Container With Microwave Interactive Web

ABSTRACT

A container that includes a microwave interactive web at least partially overlying and joined to a three-dimensional support, wherein the three-dimensional support may be formed prior to having the microwave interactive web mounted thereto. The three-dimensional support may be a preformed container that is sufficiently rigid and dimensionally stable for use in containing food.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a divisional of U.S. patent application Ser.No. 14/313,749, filed Jun. 24, 2014, which is a divisional of U.S.patent application Ser. No. 11/715,556, filed Mar. 8, 2007, now U.S.Pat. No. 8,803,049, which claims the benefit of both U.S. ProvisionalPatent Application No. 60/781,229, filed Mar. 10, 2006, and U.S.Provisional Patent Application No. 60/834,402, filed Jul. 31, 2006.

INCORPORATION BY REFERENCE

The disclosures of U.S. patent application Ser. No. 14/313,749, filedJun. 24, 2014, U.S. patent application Ser. No. 11/715,556, filed Mar.8, 2007, U.S. Provisional Patent Application No. 60/781,229, filed Mar.10, 2006, and U.S. Provisional Patent Application No. 60/834,402, filedJul. 31, 2006, are hereby incorporated by reference for all purposes asif presented herein in its entirety.

BACKGROUND OF THE INVENTION

The present invention relates to constructs for heating, browning and/orcrisping food items and, more specifically, relates to containers forheating, browning and/or crisping food items in microwave ovens.

Microwave ovens have become a principle form of heating food in a rapidand effective manner. A variety of containers for heating, browningand/or crisping food items in microwave ovens are known. For example, ina conventional manufacturing process, a microwave interactive web ispositioned over a flat paperboard blank and laminated to the blank, andthen the blank with the attached microwave interactive web is erectedinto a package. Such packages have been successfully commercialized.Nonetheless, there is a continuing need for containers that provide anew balance of properties and for improved methods of forming suchcontainers.

BRIEF SUMMARY OF SOME ASPECTS OF THE INVENTION

One aspect of the present invention is the provision of a container thatincludes a microwave interactive web at least partially overlying andjoined to a three-dimensional support, wherein the three-dimensionalsupport may be formed prior to having the microwave interactive webmounted thereto. The three-dimensional support may be a preformedcontainer that is sufficiently rigid and dimensionally stable for use incontaining food. Accordingly and in accordance with one aspect of thepresent invention, the microwave interactive web is mounted to thepreformed container so that the preformed container with the microwaveinteractive web can be used to contain a food item being heated in amicrowave oven. The microwave energy interactive web typically includesa microwave interactive material, for example a metal, supported on asubstrate, typically a polymer film. The microwave interactive materialincludes one or more features that interact with microwave energy toenhance or reduce the effects of the microwave energy on the food. Forexample, the feature may shield the food item, direct microwave energyto particular areas of the food item, and/or promote browning and/orcrisping of the surface of the food item.

According to one aspect of the present invention, the preformedcontainer may be formed of polymeric material and/or paperboard, or thelike. More specifically, the preformed container can be a polymeric trayor bowl formed by injection molding or vacuum forming (e.g., vacuumthermal-forming), or a tray or bowl that includes paperboard panels(e.g., walls) that are held together by an injection-molded frame. Inone particular example, the container may consist essentially ofpolymeric material, or even more specifically it may consist solely ofpolymeric material. Other types of preformed containers are also withinthe scope of the present invention.

In accordance with one aspect of the present invention, a constructincludes a three-dimensional support (e.g., container) and a microwaveinteractive web mounted to the container, with the web including aplurality of pleats. The pleats may be positioned in and extend along aninterior corner of the container. The interior corner of the containermay be at least partially defined by a substantially smooth surface ofthe container, with the pleats extend across the substantially smoothsurface.

The container may include a base and a plurality of side walls. The sidewalls may extend upwardly from the base and at least partially around acavity of the container. The web may be positioned in the cavity so thatit at least partially covers the base and/or at least one of the sidewalls. More specifically, the microwave interactive material of the webmay at least partially cover the base and/or one or more of the sidewalls. The microwave interactive material of the web may extend at leastpartially around, or substantially all the way around, the cavity of thecontainer. The web may include a peripheral edge that comprises a bead,and the bead may extend substantially all the way around the cavity ofthe container.

The container may include a plurality of compartments, with the webbeing in a first of the compartments. There may be a second microwaveinteractive web mounted in a second compartment of the container. Thefirst and second webs may be distinct from one another.

One aspect of the present invention relates to a method of making aconstruct that includes microwave interactive material. The method mayinclude providing a preformed container, and then mounting a microwaveinteractive web to the preformed container. In accordance with oneaspect, the mounting of the web to the preformed container comprisesmounting the web within the cavity of the preformed container.

The method may include cutting the web with a laser. This cutting mayoccur after the mounting of the web within the cavity of the container.In accordance with one aspect, the cutting of the web with the lasercomprises directing a laser beam through an opening of the container.

In accordance with one aspect of the present invention, a method ofmaking a container includes reconfiguring a microwave interactive weband mounting the web to a three-dimensional support (e.g., a preformedcontainer) while the web extends at least partially around and at leastpartially defines a cavity. The reconfiguring of the web may includeforming pleats in the web.

The method may further include heating at least a flap-like edge portionof the web to transform the flap-like edge portion of the web into abead. This heating typically occurs after the mounting and prior toplacing food in the container.

In accordance with one aspect of the present invention, a system mayinclude a container transporting apparatus for serially movingcontainers (e.g., preformed containers) along a first path of travel, aweb transporting apparatus for serially moving microwave interactivewebs along a second path of travel so that the containers and microwaveinteractive webs are superposed with respect to one another in a serialfashion, and a mounting apparatus for respectively mounting themicrowave interactive webs to the containers while they are insuperposed arrangements with respect to one another. The mountingapparatus may include a forming tool for at least partially forming acavity in a microwave interactive web that is being mounted tocontainer.

The container transporting apparatus can be a conveyor including aplurality of receptacles configured for serially traveling along anendless path. The system may further include a supplying apparatus forrespectively depositing the containers in the receptacles. The mountingapparatus may be positioned along the endless path so that thereceptacles carry the containers, with the microwave interactive websrespectively mounted thereto, in a downstream direction along theendless path and away from the mounting apparatus. The system mayfurther include a receiving apparatus that is positioned along theendless path at a position downstream from the mounting apparatus. Thereceiving apparatus may be for receiving the containers, with themicrowave interactive webs respectively mounted thereto, from thereceptacles.

As mentioned above, the preformed containers can be more generallyreferred to as “supports”. In accordance with one aspect of the presentinvention, a system for forming containers includes a supporttransporting apparatus for serially supplying supports to an installingapparatus, and a web transporting apparatus for serially providingmicrowave interactive webs to the installing apparatus. The installingapparatus may be operative to serially combine the microwave interactivewebs and the supports to form containers. Each of the containers mayinclude a support supporting a microwave interactive web, with themicrowave interactive web extending at least partially around and atleast partially defining a cavity of the container. The installingapparatus may include a forming tool that extends at least partiallyinto the cavity of the container to at least partially facilitate themounting of the microwave interactive web to the support.

The support transporting apparatus may include at least one receptacle.The forming tool and the receptacle may be mounted with respect to oneanother so that there can be relative movement between the forming tooland the receptacle, so that the forming tool and the receptacle can betransitioned between an inserted configuration and a retractedconfiguration. The inserted configuration may be characterized by theforming tool being at least partially inserted into the cavity of thereceptacle. The retracted configuration may be characterized by theforming tool being at least partially retracted from the cavity of thereceptacle. The installing apparatus may include at least one actuatorfor causing relative movement between the forming tool and thereceptacle to transition between the retracted and insertedconfigurations.

In accordance with one aspect of the present invention, a system forforming at least one container, which includes microwave interactivematerial, includes a holder for releasably holding at least onemicrowave interactive web, an apparatus (e.g., a receptacle) forsupporting at least one support (e.g., preformed container), and aforming tool mounted for moving the microwave interactive web relativeto the support to at least partially form the container, so that theforming tool extends at least partially into a cavity of the container.The holder is configured for at least tensioning the microwaveinteractive web while the forming tool moves the microwave interactiveweb relative to the support. The holder may define at least one gap forslidingly receiving the microwave interactive web. A distance extendingacross and perpendicular to the gap may be about the same as a thicknessof the microwave interactive web. The gap may define an undulatingshape, and the undulating shape may be suited for at least partiallyforming pleats in the microwave interactive web. The gap may be definedbetween a pair of dies. One of the pair of dies may be a somewhatplate-like female pleating die, and a second of the pair of dies may bea somewhat plate-like male pleating die.

Other aspects and advantages of the present invention will becomeapparent from the following.

BRIEF DESCRIPTION OF THE DRAWINGS

Having described some aspects of the invention in general terms,reference will now be made to the accompanying drawings that illustrateexemplary embodiments of the present invention and are not necessarilydrawn to scale.

FIG. 1 is a schematic plan view of a piece of a composite web thatincludes a series of microwave interactive webs that can be cut from thecomposite web and be respectively mounted to structures such as, but notlimited to, preformed containers, in accordance with exemplaryembodiments of the present invention.

FIG. 2 is a perspective view of an example of a microwave interactiveweb of the composite web of FIG. 1.

FIG. 3 is a perspective view of a conventional, polymeric, preformedcontainer to which the microwave interactive web of FIG. 2 can bemounted, in accordance with a first exemplary embodiment of the presentinvention.

FIG. 4 is a schematic, perspective view of a composite container, namelya microwave interactive web mounted to the preformed container of FIG.3, in accordance with a first version of the first exemplary embodimentof the present invention.

FIG. 5 is a schematic cross-sectional view of a portion of the compositecontainer of FIG. 4, with the cross-section taken along line 5-5 of FIG.4, and only the cross-section being shown.

FIG. 6 is a schematic, generally horizontal cross-sectional view takensubstantially along line 6-6 of FIG. 4, for illustrating pleats of themicrowave interactive web, and only the cross-section is shown.

FIG. 7 is a cross-sectional view like that of FIG. 5, except that FIG. 7is a cross section of a different composite container, namely acomposite container that is like the tray of FIG. 4 except for includingan additional layer of microwave interactive material, in accordancewith a second version of the first exemplary embodiment of the presentinvention.

FIG. 8 is a perspective view of a composite container, namely amicrowave interactive web mounted to the preformed container of FIG. 3,in accordance with a third version of the first exemplary embodiment ofthe present invention.

FIG. 9 is a perspective view of a composite container, namely amicrowave interactive web mounted to the preformed container of FIG. 3,in accordance with a fourth version of the first exemplary embodiment ofthe present invention.

FIG. 10 is a schematic, generally top plan view of portions of amanufacturing system for combining a microwave interactive web to apreformed container to create a composite container, in accordance withthe first exemplary embodiment of the present invention.

FIG. 11 is a schematic, side elevation view of an installing apparatusof the manufacturing system of FIG. 10, with a receptacle of a turntableof the manufacturing system being positioned below the installingapparatus, and a forming tool and die plate of the installing apparatusbeing in a retracted configuration.

FIG. 12 is like FIG. 11, except that reels and associated rolls ofmaterial are not shown, and the die plate is in an extendedconfiguration.

FIG. 13 is like FIG. 12, except that the forming tool is also in anextended configuration.

FIG. 14 is a schematic, isolated, perspective view of the microwaveinteractive web of the composite container of FIG. 4 in a substantiallyflat configuration. FIG. 14 is illustrative of how this microwaveinteractive web would appear, in isolation, while in the installingapparatus with the installing apparatus being in the configuration shownin FIG. 12.

FIG. 15 is a schematic, isolated, top perspective view of an anvil ofthe installing apparatus of FIG. 10.

FIG. 16 is a schematic, isolated, bottom perspective view of a die plateof the installing apparatus of FIG. 10.

FIG. 17 is a top perspective view of the anvil of FIG. 15 and the dieplate of FIG. 16 mated with one another while the die plate is in theextended configuration shown in FIGS. 12 and 13.

FIG. 18 schematically illustrates a computerized numerical control lasercutting machine cutting the composite web and remnants of the compositeweb from the microwave interactive web that has already been mounted toa preformed container that is in a representative receptacle of theturntable, with only a vertical cross-section of some of the featuresbeing shown, in accordance with a version of the first exemplaryembodiment of the present invention.

FIG. 19 is a schematic perspective view of a mounting apparatus of theinstalling apparatus of FIGS. 10-13, with the forming tool of themounting apparatus in its retracted configuration and positioned above arepresentative one of the turntable's receptacles, in accordance withthe first exemplary embodiment of the present invention.

FIG. 20 is a schematic perspective view of a portion of the mountingapparatus, showing the forming tool in greater detail, in accordancewith the first exemplary embodiment of the present invention.

FIG. 21 is a schematic perspective view of a portion of the forming toolpositioned above the representative receptacle, in accordance with thefirst exemplary embodiment of the present invention.

FIG. 22 is a schematic perspective view of a portion of the mountingapparatus showing the forming tool in its extended configuration, inwhich it extends into the representative receptacle, in accordance withthe first exemplary embodiment of the present invention.

FIG. 23 is a schematic cross-sectional view showing how the forming tooland the representative receptacle can be shaped, with the cross-sectionbeing taken vertically through the center of the forming tool and therepresentative receptacle, and only the cross-section being shown, inaccordance with the first exemplary embodiment of the present invention.

FIG. 24 is a schematic, vertical cross-sectional view of a portion of acomposite container, showing how a peripheral edge of the microwaveinteractive web of the composite container may be a flap-like featurethat is not adhered to the preformed container, in accordance with aversion of the first exemplary embodiment of the present invention.

FIG. 25 is like FIG. 24, except that the flap-like feature has beentransformed into a bead, such as through a post-treatment heatingprocess, in accordance with a version of the first exemplary embodimentof the present invention.

FIG. 26 is a schematic, top plan view of a multi-compartment compositecontainer in accordance with a version of a second embodiment of thepresent invention.

FIG. 27 is a schematic, isolated top plan view of a microwaveinteractive web in a flat configuration, wherein this microwaveinteractive web replaces one of the microwave interactive webs shown inFIG. 26, in accordance with a second version of the second embodiment ofthe present invention.

FIG. 28 is a schematic, isolated top plan view of a microwaveinteractive web in a flat configuration, wherein this microwaveinteractive web replaces one of the microwave interactive webs shown inFIG. 26, in accordance with the second version of the second embodimentof the present invention.

FIG. 29 is a schematic, partially cross-sectional view of a forming toolassociated with a vacuum pump, or the like, in accordance with a thirdexemplary embodiment of the present invention.

FIG. 30 is like FIG. 29, except that a microwave interactive web isshown drawn to the face of the forming tool, so that the microwaveinteractive web is conformed to the shape of the face of the formingtool to create a three-dimensional microwave interactive structure.

FIG. 31 is a schematic, isolated perspective view of thethree-dimensional microwave interactive structure of FIG. 30.

FIG. 32 is like FIG. 30, except that the three-dimensional microwaveinteractive structure drawn to the face of the forming tool includesholes, in accordance with a second version of the third exemplaryembodiment of the present invention.

FIG. 33 is like FIG. 32, except that it further illustrates a polymersheet that is schematically shown as being drawn toward thethree-dimensional microwave interactive structure.

FIG. 34 is like FIG. 33, except for showing that the polymer sheet hasbeen joined to the three-dimensional microwave interactive structure tocreate a composite container.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Referring now in greater detail to the drawings, in which like numeralsrefer to like parts throughout the several views, FIG. 1 is a schematicplan view of a piece of a composite web 98 that includes a series ofmicrowave energy interactive webs 100 (or simply “microwave interactivewebs”) that can be cut from the composite web 98 and be respectivelymounted to supports, in accordance with exemplary embodiments of thepresent invention. FIG. 2 is a perspective view of an acceptable exampleof a microwave interactive web 100 of the composite web 98 of FIG. 1.The microwave interaction interactive web 100 of FIG. 2 can berepresentative of each of the microwave interactive webs 100 of thecomposite web 98. As shown in FIG. 2, the microwave interactive web 100is substantially flat.

Referring to FIG. 2 in greater detail and in accordance with one exampleof a first exemplary embodiment of the present invention, the microwaveinteractive web 100 can be mounted to a conventional preformed container150 (FIG. 3). The microwave interactive web 100 shown in FIG. 2 includesa first microwave interactive element 102 comprising a metal foil bandincluding somewhat rounded corners 104 and obround apertures 106 in aspaced apart configuration. In accordance with the first embodiment, asused herein, the term “obround” refers to a shape substantiallyconsisting of two semicircles connected by parallel lines tangent totheir endpoints. The microwave interactive web 100 also includes asecond microwave interactive element 108 comprising microwaveinteractive foil segments 110 arranged in clusters in a lattice-likeconfiguration. Only a few of the foil segments 110 are identified bytheir reference numeral in FIG. 2. The first microwave interactiveelement 102 is spaced from and forms a border around the secondmicrowave interactive element 108. The first microwave interactiveelement 102 and the second microwave interactive element 108 aresupported on a polymer film substrate 112. Referring back to FIG. 1, thepolymer film substrate 112 extends between the opposite ends of thecomposite web 98.

Although a particular microwave interactive web 100 with first andsecond microwave interactive elements 102, 108 is shown and describedwith reference to FIGS. 1 and 2, each of the exemplary embodiments ofthe present invention can incorporate a wide variety of microwaveinteractive webs (e.g., the microwave interactive web 100 of FIG. 2)that include features that alter the effect of microwave energy duringheating or cooking of a food item. For example, the microwaveinteractive webs of the exemplary embodiments may be formed at leastpartially from one or more microwave energy interactive elements(hereinafter referred to as “microwave interactive elements”) (e.g., seethe microwave interactive elements 102, 108 of FIG. 2) that promotebrowning and/or crisping of a particular area of the food item, shield aparticular area of the food item from microwave energy to preventovercooking thereof, or transmit microwave energy towards or away from aparticular area of the food item. Each microwave interactive elementcomprises one or more microwave energy interactive materials or segmentsarranged in a particular configuration to absorb microwave energy,transmit microwave energy, reflect microwave energy, or direct microwaveenergy, as needed or desired for a particular microwave heatingcontainer and food item. The microwave interactive element may besupported on a microwave inactive or transparent substrate (e.g., seethe polymer film substrate 112 of FIGS. 1 and 2) for ease of handlingand/or to prevent contact between the microwave interactive material andthe food item. As a matter of convenience and not limitation, andalthough it is understood that a microwave interactive element supportedon a microwave transparent substrate includes both microwave interactiveand microwave inactive elements or components, such constructs arereferred to herein as “microwave interactive webs”.

The microwave energy interactive material may be an electroconductive orsemiconductive material, for example, a metal or a metal alloy providedas a metal foil; a vacuum deposited metal or metal alloy; or a metallicink, an organic ink, an inorganic ink, a metallic paste, an organicpaste, an inorganic paste, or any combination thereof. Examples ofmetals and metal alloys that may be suitable for use with the presentinvention include, but are not limited to, aluminum, chromium, copper,inconel alloys (nickel-chromium-molybdenum alloy with niobium), iron,magnesium, nickel, stainless steel, tin, titanium, tungsten, and anycombination or alloy thereof.

Alternatively, the microwave energy interactive material may comprise ametal oxide. Examples of metal oxides that may be suitable for use withthe present invention include, but are not limited to, oxides ofaluminum, iron, and tin, used in conjunction with an electricallyconductive material where needed. Another example of a metal oxide thatmay be suitable for use with the present invention is indium tin oxide(ITO). ITO can be used as a microwave energy interactive material toprovide a heating effect, a shielding effect, a browning and/or crispingeffect, or a combination thereof. For example, to form a susceptor, ITOmay be sputtered onto a clear polymer film. The sputtering processtypically occurs at a lower temperature than the evaporative depositionprocess used for metal deposition. ITO has a more uniform crystalstructure and, therefore, is clear at most coating thicknesses.Additionally, ITO can be used for either heating or field managementeffects. ITO also may have fewer defects than metals, thereby makingthick coatings of ITO more suitable for field management than thickcoatings of metals, such as aluminum.

Alternatively, the microwave energy interactive material may comprise asuitable electroconductive, semiconductive, or non-conductive artificialdielectric or ferroelectric. Artificial dielectrics comprise conductive,subdivided material in a polymeric or other suitable matrix or binder,and may include flakes of an electroconductive metal, for example,aluminum.

In one example, the microwave interactive element may comprise a thinlayer of microwave interactive material that tends to absorb microwaveenergy, thereby generating heat at the interface with a food item. Suchelements often are used to promote browning and/or crisping of thesurface of a food item (sometimes referred to as a “browning and/orcrisping element”). When supported on a film or other substrate, such anelement may be referred to as a “susceptor” or “susceptor film”.

As another example, the microwave interactive element may comprise afoil having a thickness sufficient to shield one or more selectedportions of the food item from microwave energy (sometimes referred toas a “shielding element”). Such shielding elements may be used where thefood item is prone to scorching or drying out during heating.

The shielding element may be formed from various materials and may havevarious configurations, depending on the particular application forwhich the shielding element is used. Typically, the shielding element isformed from a conductive, reflective metal or metal alloy, for example,aluminum, copper, or stainless steel. The shielding element generallymay have a thickness of from about 0.000285 inches to about 0.05 inches.In one aspect, the shielding element has a thickness of from about0.0003 inches to about 0.03 inches. In another aspect, the shieldingelement has a thickness of from about 0.00035 inches to about 0.020inches, for example, 0.016 inches.

As still another example, the microwave interactive element may comprisea segmented foil, such as, but not limited to, those described in U.S.Pat. Nos. 6,204,492, 6,433,322, 6,552,315, and 6,677,563, each of whichis incorporated by reference in its entirety. Although segmented foilsare not continuous, appropriately spaced groupings of such segmentsoften act as a transmitting element to direct microwave energy tospecific areas of the food item. Such foils also may be used incombination with browning and/or crisping elements, for example,susceptors.

Any of the numerous microwave interactive elements described herein orcontemplated hereby may be substantially continuous, that is, withoutsubstantial breaks or interruptions, or may be discontinuous, forexample, by including one or more breaks or apertures that transmitmicrowave energy therethrough. The breaks or apertures may be sized andpositioned to heat particular areas of the food item selectively. Thenumber, shape, size, and positioning of such breaks or apertures mayvary for a particular application depending on type of container beingformed, the food item to be heated therein or thereon, the desireddegree of shielding, browning, and/or crisping, whether direct exposureto microwave energy is needed or desired to attain uniform heating ofthe food item, the need for regulating the change in temperature of thefood item through direct heating, and whether and to what extent thereis a need for venting.

The aperture may be a physical aperture or void in the material used toform the container, or may be a non-physical “aperture”. A non-physicalaperture may be a portion of the container that is microwave energyinactive by deactivation, removal, or otherwise, or one that isotherwise transparent to microwave energy. Thus, for example, where amicrowave energy interactive material is used to form at least a portionof the container, the aperture may be a portion of the container formedwithout a microwave energy active material or, alternatively, may be aportion of the container formed with a microwave energy active materialthat has been deactivated or removed. While both physical andnon-physical apertures allow the food item to be heated directly by themicrowave energy, a physical aperture may also provide a ventingfunction to allow steam or other vapors to escape from the interior ofthe container.

As stated above, any of the above elements and numerous otherscontemplated hereby may be supported on a substrate. The substratetypically comprises an electrical insulator, for example, a polymerfilm. The thickness of the film may typically be from about 35 gauge toabout 10 mil. In one aspect, the thickness of the film is from about 40gauge to about 80 gauge. In another aspect, the thickness of the film isfrom about 45 to about 50 gauge. In still another aspect, the thicknessof the film is about 48 gauge. Examples of polymer films that may besuitable include, but are not limited to, polyolefins, polyesters,polyamides, polyimides, polysulfones, polyether ketones, cellophanes, orany combination thereof. Other non-conducting substrate materials suchas paper and paper laminates, metal oxides, silicates, cellulosics, orany combination thereof, also may be used.

In one aspect, the polymer film may comprise polyethylene terephthalate.Examples of polyethylene terephthalate films that may be suitable foruse as the substrate include, but are not limited to, MELINEX®,commercially available from DuPont Teijan Films (Hopewell, Va.), andSKYROL, commercially available from SKC, Inc. (Covington, Ga.).Polyethylene terephthalate films are used in commercially availablesusceptors, for example, the QWIKWAVE® Focus susceptor and theMICRORITE® susceptor, both available from Graphic PackagingInternational, Inc. (Marietta, Ga.).

In another aspect, the polymer film may be selected to provide a waterbarrier, oxygen barrier, or a combination thereof. Such barrier filmlayers may be formed from a polymer film having barrier properties orfrom any other barrier layer or coating as desired. Suitable polymerfilms may include, but are not limited to, ethylene vinyl alcohol,barrier nylon, polyvinylidene chloride, barrier fluoropolymer, nylon 6,nylon 6,6, coextruded nylon 6/EVOH/nylon 6, silicon oxide coated film,or any combination thereof.

One example of a barrier film that may be suitable for use with thepresent invention is CAPRAN® EMBLEM 1200M nylon 6, commerciallyavailable from Honeywell International (Pottsville, Pa.). Anotherexample of a barrier film that may be suitable is CAPRAN® OXYSHIELD OBSmonoaxially oriented coextruded nylon 6/ethylene vinyl alcohol(EVOH)/nylon 6, also commercially available from HoneywellInternational. Yet another example of a barrier film that may besuitable for use with the present invention is DARTEK® N-201 nylon 6,6,commercially available from Enhance Packaging Technologies (Webster,N.Y.).

Still other barrier films include silicon oxide coated films, such asthose available from Sheldahl Films (Northfield, Minn.). Thus, in oneexample, a susceptor may have a structure including a film, for example,polyethylene terephthalate, with a layer of silicon oxide coated ontothe film, and ITO or other material deposited over the silicon oxide. Ifneeded or desired, additional layers or coatings may be provided toshield the individual layers from damage during processing.

The barrier film may have an oxygen transmission rate (OTR) as measuredusing ASTM D3985 of less than about 20 cc/m2/day. In one aspect, thebarrier film has an OTR of less than about 10 cc/m2/day. In anotheraspect, the barrier film has an OTR of less than about 1 cc/m2/day. Instill another aspect, the barrier film has an OTR of less than about 0.5cc/m2/day. In yet another aspect, the barrier film has an OTR of lessthan about 0.1 cc/m2/day.

The barrier film may have a water vapor transmission rate (WVTR) asmeasuring using ASTM F1249 of less than about 100 g/m2/day. In oneaspect, the barrier film has a WVTR of less than about 50 g/m2/day. Inanother aspect, the barrier film has a WVTR of less than about 15g/m2/day. In yet another aspect, the barrier film has a WVTR of lessthan about 1 g/m2/day. In still another aspect, the barrier film has aWVTR of less than about 0.1 g/m2/day. In a still further aspect, thebarrier film has a WVTR of less than about 0.05 g/m2/day.

The microwave energy interactive material may be applied to thesubstrate (e.g., polymer film substrate 112 of FIGS. 1 and 2) in anysuitable manner, and in some instances, the microwave energy interactivematerial is printed on, extruded onto, sputtered onto, evaporated on, orlaminated to the substrate. The microwave energy interactive materialmay be applied to the substrate in any pattern, and using any technique,to achieve the desired heating effect of the food item.

For example, the microwave energy interactive material may be providedas a continuous or discontinuous layer or coating including circles,loops, hexagons, islands, squares, rectangles, octagons, and so forth.Examples of various patterns and methods that may be suitable for usewith the present invention are provided in U.S. Pat. Nos. 6,765,182;6,717,121; 6,677,563; 6,552,315; 6,455,827; 6,433,322; 6,414,290;6,251,451; 6,204,492; 6,150,646; 6,114,679; 5,800,724; 5,759,422;5,672,407; 5,628,921; 5,519,195; 5,424,517; 5,410,135; 5,354,973;5,340,436; 5,266,386; 5,260,537; 5,221,419; 5,213,902; 5,117,078;5,039,364; 4,963,424; 4,936,935; 4,890,439; 4,775,771; 4,865,921; andRe. 34,683, each of which is incorporated by reference herein in itsentirety. Although particular examples of patterns of microwave energyinteractive material are shown and described herein, it should beunderstood that other patterns of microwave energy interactive materialare contemplated by the present invention.

In the exemplary microwave interactive web 100 schematically shown inFIG. 2, the microwave interactive elements 102 and 108 typically have agrey or silver color and are visually distinguishable from thetransparent, colorless polymer film substrate 112. However, in someinstances, it may be desirable to provide a microwave interactive webhaving a uniform color and/or appearance. Such a microwave interactiveweb may be more aesthetically pleasing to a consumer, particularly whenthe consumer is accustomed to containers having certain visualattributes, for example, a solid color, a particular pattern, and so on.Thus, for example, the present invention contemplates using a silver orgrey toned adhesive to join the microwave interactive elements to thesubstrate, using a silver or grey toned substrate to mask the presenceof the silver or grey toned microwave interactive elements, using a darktoned substrate, for example, a black toned substrate, to conceal thepresence of the silver or grey toned microwave interactive elements,overprinting the metallized side of the microwave interactive web with asilver or grey toned ink to obscure the color variation, printing thenon-metallized side of the microwave interactive web with a silver orgrey ink or other concealing color in a suitable pattern or as a solidcolor layer to mask or conceal the presence of the microwave interactiveelements, or any other suitable technique or combination thereof.

In accordance with the exemplary embodiments of the present inventionand very generally described, the microwave interactive element ormicrowave interactive web (e.g., the microwave interactive web 100 ofFIG. 2) is mounted to a three-dimensional support (e.g., the preformedcontainer 150 of FIG. 3) that is typically dimensionally stable andmicrowave energy transparent. Various materials may be used to form thesupport (e.g., the preformed container 150 of FIG. 3). The support, likethe microwave interactive web, will typically be constructed frommaterials that are resistant to softening, scorching, combusting, ordegrading at typical microwave oven heating temperatures, for example,at about 250° F. These items may also be constructed from materials thatare resistant to softening, scorching, combusting, or degrading attypical conventional oven heating temperatures, for example, from about450° F. to about 550° F. For example, the support may be formed at leastpartially from a polymer or polymeric material. As used herein the term“polymer” or “polymeric material” includes, but is not limited to,homopolymers, copolymers, such as for example, block, graft, random, andalternating copolymers, terpolymers, etc. and blends and modificationsthereof. Furthermore, unless otherwise specifically limited, the term“polymer” shall include all possible geometrical configurations of themolecule. These configurations include, but are not limited toisotactic, syndiotactic, and random symmetries. One polymer that may besuitable for use with the present invention is polycarbonate. Otherexamples of polymers that may be suitable for use with the presentinvention include, but are not limited to, polyolefins, e.g.polyethylene, polypropylene, polybutylene, and copolymers thereof;polytetrafluoroethylene; polyesters, e.g. polyethylene terephthalate,e.g., coextruded polyethylene terephthalate; vinyl polymers, e.g.,polyvinyl chloride, polyvinyl alcohol, ethylene vinyl alcohol,polyvinylidene chloride, polyvinyl acetate, polyvinyl chloride acetate,polyvinyl butyral; acrylic resins, e.g. polyacrylate,polymethylacrylate, and polymethylmethacrylate; polyamides, e.g., nylon6,6; polystyrenes; polyurethanes; cellulosic resins, e.g., cellulosicnitrate, cellulosic acetate, cellulosic acetate butyrate, ethylcellulose; copolymers of any of the above materials; or any blend orcombination thereof.

Alternatively, all or a portion of the support (e.g., the preformedcontainer 150 of FIG. 3) may be formed at least partially from a paperor paperboard material, which may be cut into a blank prior to use inthe container. In one aspect, the support is formed from paper generallyhaving a basis weight of from about 15 to about 60 lbs/ream (i.e.,lbs/3,000 ft²), for example, from about 20 to about 40 lbs/ream. In oneparticular example, the paper has a basis weight of about 25 lbs/ream.In another aspect, the support is formed from paperboard having a basisweight of from about 60 to about 330 lbs/ream, for example, from about80 to about 140 lbs/ream. The paperboard generally may have a thicknessof from about 6 to about 30 mils, for example, from about 12 to about 28mils. In one particular example, the paperboard has a thickness of about12 mils. Any suitable paperboard may be used, for example, a solidbleached or solid unbleached sulfate board, such as SUS® board,commercially available from Graphic Packaging International, Inc. Ifneeded or desired, one or more portions of the support may be laminatedto or coated with one or more different or similar sheet-like materialsat selected panels (e.g. walls) or panel sections.

Optionally, one or more panels (e.g., walls) of the various blanks,supports, or containers described herein or contemplated hereby may becoated with varnish, clay, or other materials, either alone or incombination. The coating may then be printed over with productadvertising or other information or images. The blanks, supports, orcontainers also may be coated to protect any information printedthereon.

Furthermore, the blanks, supports, or containers may be coated with, forexample, a moisture and/or oxygen barrier layer, on either or bothsides, such as those described above. Any suitable moisture and/oroxygen barrier material may be used in accordance with the presentinvention. Examples of materials that may be suitable include, but arenot limited to, polyvinylidene chloride, ethylene vinyl alcohol, andDuPont DARTEK™ nylon 6,6.

Alternatively or additionally, any of the blanks, supports, orcontainers of the present invention may be coated or laminated withother materials to impart other properties, such as absorbency,repellency, opacity, color, printability, stiffness, or cushioning. Forexample, absorbent susceptors are described in U.S. ProvisionalApplication No. 60/604,637, filed Aug. 25, 2004, and U.S. patentapplication Ser. No. 11/211,858, to Middleton, et al., titled “AbsorbentMicrowave Interactive Packaging”, filed Aug. 25, 2005, both of which areincorporated herein by reference in their entirety. Additionally, theblanks, supports, or containers may include graphics or indicia printedthereon.

In accordance with several versions of the first embodiment, themicrowave interactive webs are respectively mounted to preformedsupports (e.g., three-dimensional supports) that can more specificallybe referred to as preformed containers, and even more specifically theycan be conventional, polymeric, preformed containers 150. FIG. 3 is anisolated perspective view of a conventional, polymeric, preformedcontainer 150 to which the microwave interactive web of FIG. 2 can bemounted, in accordance with one version of the first embodiment. Asshown in FIG. 3, the preformed container 150 is substantiallyrectangular in shape (e.g., is tray-shaped) and includes afood-supporting panel or base 152, upstanding walls 154 and somewhatrounded corners 156 that together extend around the cavity of thepreformed container, and a flange 158 that protrudes outwardly from theupper edges of the walls. The walls 154 and corners 156 extendupwardly/obliquely/outwardly from the base 152. That is, typically, theouter walls 154 are inclined outwardly so that a series of the preformedcontainers 150 can be arranged in a nested stack. However, thecontainers (e.g., preformed containers 150) described herein orcontemplated hereby may have any shape as desired, for example, apartial sphere or bowl, polygon, circle, oval, cylinder, prism, sphere,polyhedron, ellipsoid, or any other regular or irregular shape. As anadditional example, and as will be discussed in greater detail below,the containers (e.g., preformed containers 150) described herein orcontemplated hereby may include one or more interior walls or dividersthat separate food items or multiple servings of a particular food item.

One specific example of the preformed container 150 is a tray that ismade from a polyester material, for example, polyethylene terephthalate,(e.g., one hundred percent polyester material by weight) through the useof a vacuum thermal-formed process. Nonetheless and as mentioned above,a wide variety of preformed containers are within the scope of thepresent invention. For example and for each of the examples and/orversions of the first embodiment of the present invention, the preformedcontainer 150 constructed substantially solely of polymeric material canbe replaced with a support comprising a frame that is injection moldedonto a group of panels (e.g., with the panels (e.g., walls) comprisingpaperboard, or the like) to form a container, namely a bowl or tray inwhich the panels extend at least partially around, and at leastpartially define, a cavity of the container. In this regard,incorporated herein by reference is the entire disclosure of a U.S.patent application that: is entitled “Injection-Molded CompositeConstruct”; is being filed on the same day, or at least about the sameday, as the present application; claims the benefit of the same U.S.provisional patent applications as the present application, and asoriginally filed names as inventors Brian O'Hagan, Peter Blaas, ScottMiddleton, Kevin Hjort and Bruce Barnard. Throughout the DetailedDescription section of this disclosure, the preformed container 150 canbe replaced with any of the containers disclosed by the patentapplication that is incorporated by reference in the immediatelypreceding sentence.

In accordance with an exemplary method of the first embodiment of thepresent invention, the microwave interactive webs 100 (FIGS. 1 and 2)are cut from the composite web 98 and respectively mounted to multipleof the preformed containers 150 in a serial fashion to create compositecontainers, as will be discussed in greater detail below beginning withreference to FIG. 10. A wide variety of microwave interactive webs,preformed containers and composite containers are within the scope ofthe present invention. Therefore, and for example, a few examples of thewide variety of the composite containers of the first embodiment of thepresent invention are discussed in the following with reference to FIGS.4-9.

FIG. 4 is a schematic, perspective view of a composite container 200comprising a microwave interactive web 208 mounted to a preformedthree-dimensional support that is in the form of a container, or morespecifically in the form of the preformed container 150 (also see FIG.3), in accordance with a first version of the first embodiment of thepresent invention. More specifically, the microwave interactive web 208is at least partially overlying and joined to the preformed container150. The preformed container 150 can be more generally referred to as adimensionally stable microwave inactive support.

More specifically and as best understood by also referring to thecross-sectional view of FIG. 5, the microwave interactive web 208comprises a first microwave interactive element 212 (FIG. 4) and asecond microwave interactive element 214 (FIGS. 4 and 5) supported on apolymer film 216 and joined thereto using a layer of adhesive 217. Inthis example, the microwave interactive web 208 is joined to the support(e.g., preformed container 150) by a layer of a heat seal coating 218.However, in this and other versions and embodiments of the invention,other suitable methods of joining the microwave interactive web andsupport (e.g., the preformed container 150) may be used, for example,adhesive bonding, thermal bonding, ultrasonic bonding, mechanicalstitching, or any suitable process or technique. FIG. 5 is schematicbecause, for example, some of the features shown are not drawn to scaleand are exaggerated for purposes of clarity and visibility.

The first microwave interactive element 212 is generally continuous andextends around the perimeter of the base 152 (FIG. 3) of the preformedcontainer 150 and partially upward along the walls 154 (FIG. 3) of thepreformed container. In this example, the first microwave interactiveelement 212 is a metal foil band, for example, an aluminum foil, havinga thickness sufficient to shield at least partially the microwave energydirected toward the food item (not shown) contained by the compositecontainer 200. The first microwave interactive element includes obroundapertures 213.

The second microwave interactive element 214 includes two sets ofmicrowave interactive element segments 220, each including an annulargrouping 222 and a central grouping 224. Each of the segments 220 issomewhat triangular or somewhat trapezoidal in shape. However, it willbe understood that any suitable shape may be used to form the segments220, for example, circles, ovals, and other curvilinear shapes, forexample, symmetrical curvilinear shapes, triangles, squares, rectangles,and other polygonal shapes, for example, right polygonal shapes,equilateral polygonal shapes, or any combination thereof. As used hereinthe term “symmetrical curvilinear shape” means a closed curvilinearshape that can be divided in half such that the two halves aresymmetrical about an axis dividing them. As used herein, the term “rightpolygon” means a polygon that can be divided in half such that the twohalves are symmetrical about an axis dividing them. Equilateral polygonsare therefore a subset of right polygons. Each set of microwaveinteractive element segments 220 tends to act as an antenna that directsmicrowave energy to a portion of the food item, for example, that wouldotherwise tend to be underheated.

In accordance with the first version of the first embodiment, the secondmicrowave energy interactive element 214 can be formed into the desiredpattern by applying an etch-resistant coating 228 to the metal andetching the uncoated areas. However, any suitable process for formingthe element 214 may be used. In the composite container 200 of the firstversion of the first embodiment, the microwave interactive web 208 canbe replaced with a wide variety of microwave interactive webs, such asany of those disclosed herein.

In the composite container 200, the microwave interactive web 208 issomewhat pleated, for example to accommodate the microwave interactiveweb fitting snugly into rounded corners 156 (FIG. 3) of the preformedcontainer 150. FIG. 4 is schematic because, for example, numerous of thepleats are not shown in detail; only a few representative pleats 226 areschematically shown as extending substantially for the entire length ofone of the corners 156 (FIG. 3) (e.g., substantially from the bottom tothe top of the representative corner). FIG. 6 is a schematic, horizontalcross-sectional view taken substantially along line 6-6 of FIG. 4. Onlya portion of the subject corner 156 is shown in FIG. 6, and only thecross section is shown. As schematically shown in FIG. 6, thefolded-over nature of the pleats 226 is in contrast to the smoothlycurved nature of the concave inner surface 229 of the preformedcontainer 150 that at least partially defines the corner. As shown inFIG. 6, each pleat 226 includes at least two (e.g., two or more)portions of the microwave interactive web 208 that are in overlapping,face-to-face relation (e.g., face-to-face contact) with respect to oneanother. Differently shaped inner surfaces 229, such as but not limitedto pleated inner surfaces of alternative preformed containers, are alsowithin the scope of the present invention.

FIG. 7 is a cross-sectional view like that of FIG. 5, except that FIG. 7is a cross section of a portion of a base of a composite container of asecond version of the first embodiment of the present invention. Thecomposite container of the second version of the first embodiment islike the composite container 200 of the first version of the firstembodiment, except for variations noted and variations that will beapparent to those of ordinary skill in the art. The microwaveinteractive web of the composite container of the second version of thefirst embodiment further includes a browning and crisping element, forexample a susceptor comprising a layer of microwave energy interactivematerial 230. By using the susceptor comprising the layer of microwaveenergy interactive material 230 in combination with the second microwaveinteractive element 214, the effectiveness of both of these features maybe enhanced.

It will be understood that some of the features depicted in FIG. 7 arenot to scale and are exaggerated merely for purposes of clarity andvisibility. Further, it will be understood that numerous othercombinations of various microwave energy interactive elements arecontemplated hereby. Indeed, the microwave interactive web of thecomposite container of the second version of the first embodiment can bereplaced with a wide variety of microwave interactive webs, such as anyof those disclosed herein.

A third version of the first embodiment of the present invention can belike either of the first and second versions of the first embodiment,except for variations noted and variations that will be apparent tothose of ordinary skill in the art. FIG. 8 is a schematic perspectiveview of a composite container 300 comprising a microwave interactive web308 mounted to a preformed three-dimensional support that is in the formof a container, or more specifically in the form of the preformedcontainer 150 (FIG. 3), in accordance with the third version of thefirst embodiment of the present invention.

The microwave interactive web 308 is somewhat pleated, for example toaccommodate the rounded corners 156 (FIG. 3) of the preformed container150. FIG. 8 is schematic because, for example, numerous of the pleats302 are not shown in detail; only a few representative pleats 302 areschematically shown as extending substantially for the entire length ofsome of the corners (e.g., substantially from the bottom to the top ofthe representative corners). The pleats 302 of the composite container300 are like the pleats 226 of the composite container 200 (e.g., seeFIG. 6).

The microwave interactive web 308 comprises a first microwaveinteractive element 312 and a second microwave interactive element 314supported on a polymer film 316. The first microwave interactive element312 is a generally continuous metal foil that extends around theperimeter of the base 152 (FIG. 3) of the preformed container 150 andsubstantially upward along the walls 154 (FIG. 3) of the preformedcontainer. Apertures 318 that each have a somewhat obround shape aredefined by the first microwave interactive element 312 in a spaced apartconfiguration. The second microwave interactive element 314 includesfive annularly arranged sets or groups of microwave interactive elementsegments 320 arranged in a staggered configuration. Each of the segments320 within the sets is somewhat triangular or somewhat trapezoidal inshape.

In use, the foil portion of first microwave interactive element 312tends to shield the food item (not shown) in the composite container 300from microwave energy, while allowing the microwave energy to passthrough the apertures 318. Each set of microwave interactive elementsegments 320 tends to act as an antenna, directing the microwave energyto particular areas of the food item (not shown) in the compositecontainer 300. In the composite container 300 of the third version ofthe first embodiment, the microwave interactive web 308 can be replacedwith a wide variety of microwave interactive webs, such as any of thosedisclosed herein.

A fourth version of the first embodiment of the present invention can belike the other versions of the first embodiment, except for variationsnoted and variations that will be apparent to those of ordinary skill inthe art. FIG. 9 is a schematic, perspective view of a compositecontainer 400 comprising a microwave interactive web 408 mounted to apreformed three-dimensional support that is in the form of a container,or more specifically in the form of the preformed container 150, inaccordance with a fourth version of the first embodiment of the presentinvention.

The microwave interactive web 408 is pleated in the manner describedabove for the other versions of the first embodiment, although only afew representative pleats 402 are schematically shown in FIG. 9. Themicrowave interactive web 408 comprises a first microwave interactiveelement 412 and a second microwave interactive element 414 supported ona polymer film 416. The first microwave interactive element 412 is agenerally continuous metal foil that extends around the perimeter of thebase 152 (FIG. 3) of the preformed container 150 and substantiallyupward along the walls 154 (FIG. 3) of the preformed container.Apertures 418 that each have a somewhat rectangular shape or a somewhatpentagonal shape are defined within the first microwave interactiveelement 412 along the walls 154 of the container 400 in a spaced apartconfiguration. The second microwave interactive element 414 includesfive annularly arranged groups or sets of microwave interactive elementsegments 420 in a staggered configuration. Each of the segments 420within the sets is somewhat triangular or somewhat trapezoidal in shape.

In use, the foil portion of the first microwave interactive element 412tends to shield the food item (not shown) in the composite container 400from microwave energy, while allowing the microwave energy to passthrough the apertures 418. In accordance with the fourth version of thefirst embodiment, the microwave interactive element segments 420 are incombination with a susceptor, so that in addition to acting as antennafor directing the microwave energy, each set of microwave interactiveelement segments 420 tends to act as a shielding element upon exposureto microwave energy, thereby decreasing the amount of microwave energythat passes through the base 152 (FIG. 3) of the composite container400. In the composite container 400 of the fourth version of the firstembodiment, the microwave interactive web 408 can be replaced with awide variety of microwave interactive webs, such as any of thosedisclosed herein.

An acceptable example of an intermittent motion machine or manufacturingsystem 500 and associated methods for forming the composite containersof the first embodiment (e.g., the composite containers 200, 300, 400discussed above) is discussed in the following beginning with FIG. 10,in accordance with the first embodiment. In the manufacturing system500, various process steps occur in concerted cycles of movement andrest to create a generally continuous overall manufacturing process.While certain features and steps are described herein, it is understoodthat numerous other features or steps may be added or used to replacethose described herein. Although the manufacturing system 500 isprimarily described in the following in the context of anintermittent-motion type of manufacturing system, it may be modified tobe, or to be more like, a continuous-motion manufacturing system.

As best understood with reference to the schematic top plan view of FIG.10, the manufacturing system 500 includes a container transportingapparatus for serially moving containers along a path of travel. Asshown in FIG. 10, the container transporting apparatus is in the form ofa rotary turntable 502 type of conveyor that defines an endless circularpath of travel, although other types of conveyors are within the scopeof the present invention, including conveyors with upper and lower runs.

The turntable 502 cycles through a series of indexed positions orstations, and the stations can be respectively equipped with a supplyingapparatus 504, pretreating apparatus 506, installing apparatus 508,post-treating apparatus 510, and receiving apparatus 512. As shown inFIG. 10, the upper surface 513 of the turntable 502 includes orotherwise has associated therewith upwardly open, cavity-like,container-receiving receptacles 514 a-514 e in a number corresponding tothe number of stations around the turntable 502. As shown in FIG. 10,the receptacles 514 b-514 d are respectively hidden from view beneaththe pretreating, installing and post-treating apparatuses 506, 508, 510;therefore, these hidden receptacles are schematically illustrated bydashed lines. Additional receptacles (e.g., like receptacles 514 a-514e) may be incorporated in the turntable 502 to allow for theincorporation of additional stations in the manufacturing system 500.The manufacturing system may alternatively include a lesser number ofstations and receptacles.

As will be discussed in greater detail below, the manufacturing system500 includes mechanism(s) for controlling the coordinated operation ofthe components of the manufacturing system, and an electrical centralcontroller 516 with a microprocessor, or the like, can be central to themechanisms for controlling the coordinated operation according to thefirst embodiment of the present invention. Alternatively, the electricalcentral controller 516 could be replaced with a mechanical or pneumaticcontrol system, or any other type of suitable control system forcoordinating the operation of the respective components of themanufacturing system 500.

As schematically shown in FIG. 10, the central controller 516communicates via a signal communication path 518 with the controller ofa motor 520 that drives the rotatably mounted turntable 502. As shown inFIG. 10, the motor 520 and associated drive belt or chain and pulleys orsprockets are hidden from view beneath the turntable's upper surface513; therefore, they, like some of the signal communication paths areschematically shown by dashed lines. Similarly, the central controller516 communicates via a signal communication path 521 with a positionsensor 522 that monitors the rotary position of the turntable 502. Theposition sensor 522 can be any type of sensor for detecting andreporting the rotary position of the turntable 502 to the centralcontroller 516. For example, the position sensor 522 can be an opticalsensor or Hall effect sensor that senses position-indicating marks,magnets or the like (not shown) on the peripheral edge of, or at anotheracceptable position with respect to, the turntable 502. The centralcontroller 516 also respectively communicates, such as via signalcommunication paths 530 a-530 e, with the other components of themanufacturing system, typically so that the position of the turntable502 determines the initiation of the operations of the supplyingapparatus 504, pretreating apparatus 506, installing apparatus 508,post-treating apparatus 510, and receiving apparatus 512, as will bediscussed in greater detail below. The signal communication paths 518,521, 530 a-530 e of the manufacturing system 500 can be any type ofconventional signal communication paths that would be sufficient. Forexample, they can be electrical wires that extend all the way betweenthe respective components, or they can be any type of conventionalwireless communication systems, such as infrared communication systems,radio frequency communication systems, or the like.

The central controller 516 operates in a coordinated fashion with themotor 520 and the position sensor 522 so that, as shown in FIG. 10, theturntable 502 rotates in a clockwise direction between five positions,with the turntable remaining stationary in each of the five positionsfor a predetermined period of time that is sufficient for theapparatuses 504, 506, 508, 510, 512 to complete their functions, as willbe discussed in greater detail below.

In the first position of the turntable 502, the receptacle 514 a isadjacent the supplying apparatus 504, the receptacle 514 b is adjacentthe pretreating apparatus 506, the receptacle 514 c is adjacent theinstalling apparatus 508, the receptacle 514 d is adjacent thepost-treating apparatus 510, and the receptacle 514 e is adjacent thereceiving apparatus 512. In the turntable's second position, whichdirectly follows the first position of the turntable 502 after thepredetermined period of time, the receptacle 514 e is adjacent thesupplying apparatus 504, the receptacle 514 a is adjacent thepretreating apparatus 506, the receptacle 514 b is adjacent theinstalling apparatus 508, the receptacle 514 c is adjacent thepost-treating apparatus 510, and the receptacle 514 d is adjacent thereceiving apparatus 512. In the turntable's third position, whichdirectly follows the second position of the turntable 502 after thepredetermined period of time, the receptacle 514 d is adjacent thesupplying apparatus 504, the receptacle 514 e is adjacent thepretreating apparatus 506, the receptacle 514 a is adjacent theinstalling apparatus 508, the receptacle 514 b is adjacent thepost-treating apparatus 510, and the receptacle 514 c is adjacent thereceiving apparatus 512. In the turntable's fourth position, whichdirectly follows the third position of the turntable 502 after thepredetermined period of time, the receptacle 514 c is adjacent thesupplying apparatus 504, the receptacle 514 d is adjacent thepretreating apparatus 506, the receptacle 514 e is adjacent theinstalling apparatus 508, the receptacle 514 a is adjacent thepost-treating apparatus 510, and the receptacle 514 b is adjacent thereceiving apparatus 512. In the turntable's fifth position, whichdirectly follows the fourth position of the turntable 502 after thepredetermined period of time, the receptacle 514 b is adjacent thesupplying apparatus 504, the receptacle 514 c is adjacent thepretreating apparatus 506, the receptacle 514 d is adjacent theinstalling apparatus 508, the receptacle 514 e is adjacent thepost-treating apparatus 510, and the receptacle 514 a is adjacent thereceiving apparatus 512.

In some situations, it might be acceptable for the manufacturing system500 to include a mechanical drive system, with suitable linkages,gearing and the like, by way of which one or more features of one ormore of the apparatuses 504, 506, 508, 510, 512 are driven or at leastpartially driven by the turntable and/or its motor 520. On the otherhand, and in accordance with the first embodiment, the supplyingapparatus 504, pretreating apparatus 506, installing apparatus 508,post-treating apparatus 510, and receiving apparatus 512 each includetheir own power supply(s), controller(s) and other features needed tocarry out their respective functions, with their controllers beingrespectively connected to the central controller 516 via the signalcommunication paths 530 a-530 e for purposes of providing the exemplarycoordinated operations that are discussed below.

In the following, for the purpose of providing a representative example,operations are discussed in the context of the turntable 502 moving therepresentative receptacle 514 a sequentially to the stations of themanufacturing system 500. Nonetheless and in accordance with the firstembodiment, each of the receptacles 514 a-514 e is moved along theendless flowpath defined by the turntable 502, and the apparatuses 504,506, 508, 510, 512 serially and respectively act upon the contents ofthe receptacles 514 b-514 e in the same manner in which they act uponcontents of the receptacle 514 a.

As best understood with reference to FIG. 10, a cycle for the receptacle514 a begins with the turntable 502 being stationary while thereceptacle 514 a is empty and adjacent to the supplying apparatus 504.For ease of explanation, this position is referred to herein as the“first position”, although the process can be described with differentterms and other frames of reference. At the first position, thesupplying apparatus 504 typically retrieves a pre-formed microwaveinactive support, such as the conventional preformed container 150 (FIG.3). As schematically shown in FIG. 10, the preformed container 150 isreceived from a stack 532 of preformed containers. The stack 532 may bemaintained in a hopper or other suitable stacking device. Any suitablestacking device or other device for supplying preformed containers 150may be used, for example, a moving conveyor or gravity feed, with thepreformed containers typically being provided in a controlled fashion tothe supplying apparatus 504. In one specific example, the supplyingapparatus 504 can more specifically be a de-nesting and transferringdevice, or even more specifically a “pick-and-place” feeder or feedingunit. Such pick-and-place feeders are commercially available, forexample, from Minnesota Automation (Crosby, Minn.). Minnesota Automationis affiliated with Graphic Packaging International, Inc. (Marietta,Ga.). Pick-and-place feeding units typically come in one of two basicformats: reciprocating and rotary. In the first embodiment, thesupplying apparatus 504 comprises a reciprocating pick-and-place unit.However, it may also be possible to use a rotary pick-and-place unit, orany other suitable unit, such as a gravity or conveyor feed unit or thelike, to place a preformed container 150 or other suitable support inthe receptacle 514 a.

The supplying apparatus 504, when in the form of a pick-and-placefeeding unit, typically moves one or more vacuum cups into contact withone of the preformed containers 150 (FIG. 3) in the stack 532. Thevacuum cup then “grips” the preformed container 150 and removes it fromthe stack 532. In doing so, a vacuum may be created between thepreformed container 150 being removed and the remaining preformedcontainers 150 in the stack 532. In an effort to prevent misfeeding or“double-feeding”, the stack 532 may be vibrated or bounced in itshopper. Also in an effort to prevent misfeeding or double-feeding, thesupplying apparatus 504 can further include a rotary screw device orother suitable device for removing one of the preformed containers 150from the stack 532 at a time, so that the pick-and-place feeding unit“grabs” the preformed container 150 that has already been removed fromthe stack 532. The preformed container 150 that has been “grabbed” bythe pick-and-place feeding unit is transported by the pick-and-placefeeding unit to proximate the receptacle 514 a. Then, the pick-and-placeunit typically places the preformed container 150 into the receptacle514 a. After placing the preformed container 150 in the receptacle 514a, the pick-and-place unit releases the preformed container 150 in thereceptacle 514 a, and the transporting arm or the like of thepick-and-place unit is moved away from the receptacle 514 a.

Then, the turntable 502 is rotated to the next position, so that thereceptacle 514 a containing the preformed container 150 (FIG. 3) isadjacent to (e.g., within) the pretreating apparatus 506. At this“second” position, the optional pretreating apparatus 506 can pre-treatthe preformed container 150 in the receptacle 514 a. The pretreatingcarried out by the pretreating apparatus 506 can be a heat treatmentand/or a corona treatment for enhancing the mounting/bonding to becarried out at the next step by the installing apparatus 508.

More specifically, the pretreating apparatus 506 can include adownwardly open chamber that defines a cavity that is open to and/or inreceipt of the preformed container 150 (FIG. 3) in the receptacle 514 awhile the receptacle 514 a is in the second position. The chamber of thepretreating apparatus 506 can be in the form of an oven that includesone or more heating elements or the like, and/or the pretreatingapparatus can include equipment for generating a corona atmospherewithin the chamber of the pretreating apparatus or for otherwise coronatreating the preformed container 150.

After the optional pretreatment, the turntable 502 is rotated to thenext position, so that the receptacle 514 a containing the optionallypretreated, preformed container 150 (FIG. 3) is adjacent to theinstalling apparatus 508. Very briefly described, and as will bediscussed in greater detail below, at this “third position” a microwaveinteractive web (e.g., see the microwave interactive web 100 of FIG. 2)is mounted to the preformed container 150 in the receptacle 514 a, tocreate a composite container (e.g., see the composite containers 200,300, 400 of FIGS. 4, 8 and 9).

FIG. 11 is a schematic, side elevation view of the preformed container150 in the receptacle 514 a in the third position, in which they arepositioned beneath the installing apparatus 508. The installingapparatus 508 of the first embodiment includes a web transportingapparatus 540, a cutting apparatus 542 and a mounting apparatus 544. Aswill be discussed in greater detail below, the cutting apparatus 542 ofthe version of the first embodiment that is illustrated in FIGS. 11-13includes a die plate 546 that carries a cutter in the form of one ormore blades or knives 548 (e.g., “steel rules” that can be generallycharacterized as being long razor plates) or other cutting devices forcutting the microwave interactive web 100 (also see FIGS. 1 and 2) fromthe composite web 98 (also see FIG. 1). The mounting apparatus 544includes a forming tool 550 for mounting the microwave interactive web100 to the preformed container 150 in the receptacle 514 a, to createthe composite container. When the receptacle 514 a containing thepreformed container 150 initially becomes adjacent to the installingapparatus 508, the installing apparatus is in the configuration shown inFIG. 11, in which the forming tool 550 and the die plate 546 are each intheir retracted configurations.

The web transporting apparatus 540 includes an upstream reel 552 forcarrying an upstream roll from which the composite web 98 is drawn. Theupstream reel 552 can be a traditional unwind stand with a brakingdevice for maintaining optimal tension in the composite web 98.Additionally, a web splicing apparatus (not shown) may be provided toallow for one expiring roll of composite web 98 to be attached to a newone. A pair of driven nip rolls (not shown) or any other suitablemechanism may be used to unwind the composite web 98 from the upstreamreel 552 at the desired rate. The drawing of the composite web 98 fromthe upstream reel 552 may also be aided by the winding-up action of adownstream reel 554 upon which remnants 556 (e.g., a web of remnants) ofthe composite web 98 are wound into a roll, as will be discussed ingreater detail below. At least some of the remnants 556 can also oralternatively be collected by other collection mechanisms, such as thosethat draw the remnants under the force of a partial vacuum. Also,conventional devices (not shown) can be provided between the upstreamand downstream reels 552, 554 for aiding in the proper guiding andpositioning of the composite web 98 and remnants 556. These additionaldevices can include conveyor type devices such as conventional tenterframes, or the like, for carrying or otherwise guiding and/or supportingthe side edges of the composite web 98 and remnants 556.

The composite web 98 will be moved (e.g., indexed) in a controlledmanner to ensure that one of the microwave interactive webs 100 of thecomposite web 98 is in register with the preformed container 150 in thereceptacle 514 a that is at the third position. This can be facilitatedusing a sensor, such as a photo-eye device or other device, that detectsthe position of one or more of the microwave interactive webs 100 of thecomposite web 98, or another appropriate frame of reference provided bythe composite web, and controls the components for drawing the compositeweb 98 and remnants 556 along the path of travel that extends betweenthe upstream and downstream reels 552, 554. The path of travel thatextends between the upstream and downstream reels 552, 554 isschematically illustrated in FIG. 10 by the arrows 555 drawn with dashedlines.

The tray 150 in the receptacle 514 a that is at the third position hastraveled along an upstream portion of the path of travel defined by theturntable 502 (FIG. 10), and the receptacle 514 a will subsequentlytravel along a downstream portion of the path of travel defined by theturntable. The path of travel of the composite web 98/remnants 556,which extends between the upstream and downstream reels 552, 554,extends above and crosses the receptacle's path of travel defined by theturntable 502. The web transporting apparatus 540 is operated so that amicrowave interactive web 100 of the composite web 98 is moved along thepath of travel defined by the web transporting apparatus, so that themicrowave interactive web is superposed with the tray 150 in thereceptacle 514 a that is at the third position. More specifically, themicrowave interactive web 100 is moved to a position in which it isvertically aligned with and positioned above the tray 150 in thereceptacle 514 a that is at the third position.

The side of the composite web 98 that includes the above-discussed oneor more microwave interactive elements may be provided with aheat-activated adhesive or a heat seal coating perhaps prior to beingwound into the form a supply roll that is received by the upstream reel552. Alternatively, an adhesive or heat seal coating may be applied tothe side of the composite web 98 that includes the one or more microwaveinteractive elements after being unwound from the upstream reel 552 andtypically prior to reaching the position in which the microwaveinteractive web 100 to be mounted is vertically aligned with andpositioned above the tray 150 in the receptacle 514 a that is at thethird position. The adhesive or heat seal coating may be applied in anysuitable manner including, but not limited to, one or more of rollcoating, printing, spraying, dipping, or other processing techniques.For example, FIG. 11 schematically illustrates the adhesive or heat sealcoating being applied at a nip defined between an upper roller 558 and alower roller 560 that is partially immersed in a bath 562 of theadhesive or heat seal coating. Alternatively, the adhesive, heat sealcoating or other suitable material may initially be applied to theinterior of the preformed container 150 instead of, or in addition to,being initially applied to the composite web 98.

The cutting apparatus 542 is mounted so that it is aligned with thesuperpositioned microwave interactive web 100/preformed container150/receptacle 514 a in the third position. In accordance with the firstembodiment, the cutting apparatus 542 includes the overhead, platen-typedie plate 546 that is positioned above a fixed, plate-like anvil 564(e.g., die). In the third position, the receptacle 514 a and thepreformed container 150 that it contains are positioned below the anvil564, and the microwave interactive web 100 that is to be mounted ispositioned between the die plate 546 and the anvil 564 while the dieplate is in its retracted configuration shown in FIG. 11.

As mentioned above and in accordance with one version of the firstembodiment, the lower face of the die plate 546 includes one or moreknives 548 with downwardly oriented cutting tips for cutting themicrowave interactive web 100, which is to be mounted, from thecomposite web 98. This cutting is facilitated by the die plate 546 beingmoved to an extended configuration shown in FIG. 12, such as through theaction of pneumatic actuators (not shown) or the like, or by any othersuitable means. In the extended configuration of the die plate 546, theknives 548 cut the microwave interactive web 100, which is to bemounted, from the composite web 98, and the tips of the knives typicallyabut the anvil 564.

As will be discussed in greater detail below, the cutting apparatus 542can be in many different configurations. For example, the fixed anvil564 that stays proximate to (e.g., aligned with) the die plate 546 couldbe omitted. As an alternative to the fixed anvil 564, the turntable 502(FIG. 10) can include anvils that respectively encircle each of thereceptacles 514 a-514 e. Irrespective, the face of the die plate 546 caninclude die rubber projections (not shown), or other suitable means,such as on opposite sides of each of the knives 548, for holding themicrowave interactive web 100 that is to be mounted and the remnants 556stationary against the anvil 564 while the die plate is in its extendedconfiguration and the forming tool 550 is in its retractedconfiguration, as shown in FIG. 12.

For example and not for the purpose of limiting the scope of the presentinvention, some aspects of the manufacturing system 500 will bedescribed in the following in the context of the composite container 200(FIG. 4) of the first version of the first exemplary embodiment. In thisregard, FIG. 14 is a schematic, isolated, perspective view of themicrowave interactive web 208 of the composite container 200 of FIG. 4in a substantially flat configuration. FIG. 14 is illustrative of howthis microwave interactive web 208 would appear, in isolation, while inthe installing apparatus 508 (FIGS. 10-13) after the installingapparatus is in the configuration shown in FIG. 12 and before theinstalling apparatus is in the configuration shown in FIG. 13.

After the configuration of FIG. 12, the configuration of FIG. 13 isachieved by moving the forming tool 550 to its extended configuration.More specifically, the forming tool is forced downwardly, so that itpasses through both a central opening 566 (FIGS. 16 and 17) in the dieplate 546 and a central opening 568 (FIGS. 15 and 17) in the anvil 564,and extends into the cavity of the preformed container 150 (FIG. 3) inthe receptacle 514 a. In the process, the previously cut microwaveinteractive web 208 (FIG. 14) is released from (e.g., pulled away from)the rubber projections of the die plate 546, or the like, and forcedinto the cavity of preformed container 150 in the receptacle 514 a.During this process, the forming tool 550 engages the microwaveinteractive web 208 and the microwave interactive web 208 is caused toconform to the shape of respective portions of both the forming tool 550and the preformed container 150. That is, the microwave interactive web208 is bent so that it defines a cavity that corresponds to therespective portion of the forming tool 550. In this regard, FIG. 13schematically illustrates the forming tool 550 extending into the cavitydefined by the microwave interactive web 208, and the cavity defined bythe microwave interactive web 208 conforming to the shape of therespective portions of the forming tool. Stated differently and inaccordance with the first embodiment, the forming tool 550 pushes themicrowave interactive web 208 through the central opening 568 in theanvil 564 and into the cavity of the preformed container 150 in thereceptacle 514 a. Accordingly, the forming tool 550 of the firstembodiment can be characterized as a pusher, since it pushes themicrowave interactive web 208 as described above.

The previously cut microwave interactive web 208 (FIG. 14) is mounted tothe interior surface of the preformed container 150 (FIG. 2) in thereceptacle 514 a in response to being forced into the cavity of thepreformed container by the forming tool 550. More specifically, afterpressing the microwave interactive web 208 onto the cavity of thepreformed container 150 in the receptacle 514 a, the forming tool 550typically remains in this extended configuration for a durationsufficient to activate the adhesive or heat seal coating and therebyjoins the microwave interactive web 208 to the preformed container 150in the receptacle 514 a, thereby forming the resulting compositecontainer 200 (FIG. 4). When heat is used to activate the adhesive orheat seal coating that bonds the microwave interactive web 208 to thepreformed container 150, the forming tool 550 may be heated to atemperature within a range of from about 200° F. to about 400° F., forexample from about 225° F. to about 350° F., or from about 250° F. toabout 300° F. Electric resistance heaters (not shown) or the like can bewithin or mounted to the forming tool 550 for this purposes, or theforming tool may include internal passageways (not shown) for receivinga flow of heated oil, or the like. Any type of heater that carries outthe heating in a satisfactory manner may be used. If such heaters areused, the receptacles 514 a-514 e may be associated with one or morefeatures (e.g., cooling fins) that assist with cooling of the compositecontainer 200 after the sealing/bonding process to minimize warpingand/or buckling of the container. Any suitable cooling elements orfeatures may be used for cooling one or more of the receptacles 514a-514 e or the composite containers within the receptacles 514 a-514 e.The cooling can be provided by features that circulate a cooling medium,such as water or air, or any other type of cooling or refrigerationsystem that can provide the desired heat transfer. In some situations,this heating and cooling may not be required.

In the above, the adherence between the microwave interactive web 208and the preformed container 150 is discussed as being at least partiallyfacilitated by an adhesive or heat seal coating activated by heat and/orpressure. One such coating is a polyester heat seal coating that iscommercially available from Coim (United Kingdom) under the trade nameEX-8056 HEAT SEAL. In one example, the adhesive or heat seal coating maycomprises a thermosetting polymeric material, a thermoplastic polymericmaterial, or any combination thereof. Such coatings may be applied inany amount needed to achieve the desired adhesion between the materials.More generally, the adherence between the microwave interactive web 208and the preformed container 150 can be provided using adhesive bonding,thermal bonding, ultrasonic bonding, or any other suitable technique.

As mentioned above and in accordance with one acceptable example, theforming tool 550 remains in its extended configuration for a durationsufficient to activate the adhesive or heat seal coating and join themicrowave interactive web 208 to the preformed container 150 in thereceptacle 514 a, thereby forming the resulting composite container 200.Thereafter, both the forming tool 550 and the die plate 546 are moved totheir retracted positions shown in FIG. 11, so that: 1) the turntable502 (FIG. 10) can be rotated so that the preformed container 150 that isbeing carried by the next receptacle 514 b (FIG. 10) becomes positionedbeneath/vertically aligned with the cutting apparatus 542 and theforming tool 550, at which time the rotation of the turntabletemporarily ceases; and 2) the web transporting apparatus 540 (FIG. 11)can resume its above-described transporting functions, so that the nextmicrowave interactive web 208 in the composite web 98 can be moveddownstream (along the path of travel established by the web transportingapparatus) to be superposed with the preformed container 150 that isbeing carried by the receptacle 514 b, at which time the transportingfunction provided by the transporting apparatus temporarily ceases. Thatis and in accordance with the first embodiment, the incrementaltransporting operations of the turntable 502 and web transportingapparatus 540: 1) occur while both the forming tool 550 and the dieplate 546 are in their retracted positions shown in FIG. 11; 2) do notoccur while the die plate and/or the forming tool are in their extendedconfigurations respectively shown in FIGS. 12 and 13; and 3) resume when(e.g., in response to) both the forming tool and the die plate returningto their retracted positions shown in FIG. 11.

As discussed in greater detail below, the cutting apparatus 542 (FIGS.11-13) can be in many different configurations. For example, thereciprocating die plate 546 with the knives 548 may be omitted in analternative embodiment. Omitting the reciprocating die plate 546 canresult in the incremental transporting operations of the turntable 502and web transporting apparatus 540: 1) occurring while the forming tool550 is in its retracted position; 2) not occurring while the formingtool is in its extended configuration; and resuming when (e.g., inresponse to) the forming tool returning to its retracted position. Thatis, there can be variations to the aspects of the present invention thatrelate to the various simultaneous and sequential steps of themanufacturing system 500.

Referring to the cutting apparatus 542 (FIGS. 11-13) in greater detail,FIG. 15 is a schematic, isolated, top perspective view of the generallyplate-like anvil 564 of the cutting apparatus, and FIG. 16 is aschematic, isolated, bottom perspective view of the die plate 546 of thecutting apparatus. As mentioned above in accordance with one example ofthe first embodiment, the die plate 546 carries one or more knives 548(FIGS. 11-13) or other cutting devices (e.g., steel rules that can begenerally characterized as being long razor plates) for cutting themicrowave interactive web 208 from the composite web 98. Although theknives 548 are not shown in FIG. 16, they could be mounted at anappropriate place on the die plate 546, such as around the periphery ofa raised portion 572 of the die plate or in one or more grooves in thedie plate. Alternatively the knives 548 can be omitted, as discussed ingreater detail below.

As mentioned above, the anvil 564 includes a central opening 568 throughwhich the forming tool 550 extends when the forming tool is in itsextended configuration shown in FIG. 13. Likewise, the die plate 546includes a central opening 566 through which the forming tool 550extends when the forming tool is in its extended configuration. In theembodiment shown in FIGS. 15-17, the anvil 564 defines a recess 570 thatextends around its central opening 568, and the die plate 546 includes araised area 572 that extends around its central opening 566. When thedie plate 546 is in its extended configuration shown in FIGS. 12 and 13,it may mate with the anvil, such as by the raised area 572 of the dieplate fitting into the recess 570 of the anvil 564. FIG. 17 is a topperspective view of the anvil 564 of FIG. 15 and the die plate 546 ofFIG. 16 mated with one another in the manner described immediatelyabove.

To assist with forming orderly pleats 226 (FIGS. 4 and 6) of themicrowave interactive web 208 in the interior corners of the compositecontainer 200, one or both of the die plate 546 and the anvil 564 caninclude features for initiating or otherwise at least partiallycontrolling the pleats/pleating. For example, these features can benotches, groves, protrusions or any other suitable features. As oneparticular example shown in FIGS. 15 and 16, female pleating plates 574(e.g., pleating dies) are mounted to the die plate 546, and malepleating plates 576 (e.g., pleating dies) are mounted to the anvil 564.Alternatively, the female pleating plates 574 can be mounted to theanvil 564, and male pleating plates 576 can be mounted to the die plate546. The pleating plates 574, 576 extend at least partially around therespective central openings 566, 568 and they may extend completelyaround the central openings (e.g., when the containers are round bowls).Each of the female pleating plates 574 includes elongate recesses (e.g.,indentions). Each of the male pleating plates 576 includes elongateprotrusions. Protrusions of the male pleating plates 576 are for beingrespectively at least partially received in, or for being proximate,recesses of the female pleating plates 574.

More specifically, as the microwave interactive web 208 is being forcedinto the preformed container 150, respective portions of the microwaveinteractive web are positioned between, and slide between, therespectively mated female and male pleating plates 574, 576 in a mannerthat seeks to optimally control the pleating of the microwaveinteractive web. Although hidden from view in FIG. 17, the female andmale pleating plates 574, 576 are respectively mated with respect to oneanother while the anvil 564 and die plate 546 are mated together asshown in FIG. 17. For a representative pair of mated female and malepleating plates 574, 576, the plates/dies of the mated pair are inopposing face-to-face relation with respect to one another and define anarrow gap (having an undulating shape) therebetween, with the distanceacross and perpendicular to the gap being about the same as thethickness of the microwave interactive web 208. The microwaveinteractive web 208 slides through this gap. This sliding through thegap defined between the pleating plates 574, 576, which occurs inresponse to the microwave interactive web 208 being forced toward/intothe preformed container 150, tensions/controls tensioning of themicrowave interactive web in a manner that aids in the formation of theorderly pleats 226. Accordingly, the die plate 546 and the anvil 564, ormore specifically the pleating plates 574, 576, are cooperative toreleasably hold and tension the microwave interactive web 208 while theforming tool 550 moves the microwave interactive web.

As alluded to above, the pleating plates 574, 576 can be more generallyreferred to as dies, and they can be replaced with a variety of types ofdies or other features suitable for carrying out the desiredfunctionality, such as, but not limited to, features formed in orotherwise defined by the die plate 546 and the anvil 564. Also, whereasthe above-discussed gap has been described as being respectively definedbetween the pleating plates 574, 576, it can be more generallycharacterized as being defined between the die plate 546 and the anvil564, such as when the pleating plates 574, 576 are omitted, such as whenthe pleating plates 574, 576 are replaced with features formed in orotherwise defined by the die plate 546 and the anvil 564. Other changesare also within the scope of the present invention.

It can be advantageous for the male pleating plates 576 to be mounted inthe recess 570 of the anvil 564 so that the composite web 98/microwaveinteractive web 208 can slide across or otherwise be proximate the uppersurface of the anvil while they are being moved by the web transportingapparatus 540 (FIG. 11). However, a wide variety of differentarrangements are within the scope of the present invention. For example,although only the corners of the microwave interactive web 208 aremanipulated with the pleating plates 574, 576 in the illustratedembodiment, the pleating plates may be configured in numerous ways toprovide pleats or other patterns in other portions of microwaveinteractive webs. For example, although the central openings 566, 568 ofthe die plate 546 and anvil 564, the forming tool 550 and the pleatingplates 574, 576 are typically shown herein such that they are for usewhen the preformed containers and composite containers are trays, thevarious components can be reconfigured such that the preformedcontainers and composite containers are other shapes, such asbowl-shaped.

In some versions of the manufacturing system 500 of the firstembodiment, the knives 548 (FIGS. 11-13) are omitted from the die plate546, and the microwave interactive web 208 is cut, torn or otherwiseseparated from the composite web 98 by way of one or more othermechanisms. In one version of the first embodiment of the manufacturingsystem 500 that can be best understood with reference to FIG. 18, themicrowave interactive web 208 is cut from the composite web 98 and theremnants 556 by a laser beam 580 that is schematically illustrated by adashed line in FIG. 18. In one particular example, the laser 582 is usedafter the microwave interactive web 208 has been mounted to thepreformed container 150 and at least the forming tool 550 (FIGS. 11-13)has been returned to its retracted configuration. Cutting at thisrelatively late time may be advantageous, for example, because it canallow the pleating plates 574, 576 (FIGS. 15 and 16) to at leastpartially control movement of the microwave interactive web 208 for alonger period of time than if the microwave interactive web is cut toits final size before the forming tool 550 is moved to its extendedconfiguration.

Even though the pleating plates 574, 576 might be interacting solelywith what will become remnants 556 of the composite web 98 toward theend of the downward movement of the forming tool 550, this can stillhelp to control the formation of the pleats 226 (FIGS. 4 and 6) in themicrowave interactive web 208. For example, because the microwaveinteractive web 208/what will become remnants 556 of the composite web98 slide between the pleating plates 574, 576 throughout the completionof the downward stroke of the forming tool 550, tension can bemaintained/controlled in the composite web 98 throughout the completionof the downward stroke of the forming tool 550, with thistension/controlling of the tension aiding in the formation of theorderly pleats 226. Even though the downward stroke of the forming tool550 is referred to in the foregoing, it is within the scope of thepresent invention for the forming tool and other components to bepositioned such that the present invention is not limited to anyparticular orientation of the forming tool and other components.

Generally described, the laser 582 and/or mirrors for reflecting thelaser beam 580 can be movably mounted and controlled by a computercontroller (e.g., a computerized numerical control (“CNC”) cuttingmachine that uses the laser for cutting). As a more specific examplethat is schematically shown in FIG. 18, an actuator mechanism 584carries the laser 582. The actuator mechanism 584 can include one ormore electric motors or other types of suitable actuators along with oneor more movable arms, turret-like mechanisms or other types of featuresfor facilitating controlled movement of the laser 582. For controlpurposes, the laser 582 and the actuator mechanism 584 are respectivelyin communication with a local controller 586 (e.g., a CNC controller) byway of signal communication paths 588, 590. For coordinating with theoperations of the other components of the overall system 500 (FIG. 10),the local controller 586 is operatively in communication with thecentral controller 516 (FIG. 10) via one or more signal communicationpaths 592 and/or 530 c (FIG. 10). The signal communication paths 588,590, 592 can be any type of conventional signal communication paths thatwould be sufficient. For example, they can be electrical wires thatextend all the way between the respective components, or they can be anytype of conventional wireless communication systems, such as infraredcommunication systems, radio frequency communication systems, or thelike.

In the example shown in FIG. 18, the microwave interactive web 208 hasbeen mounted to the preformed container 150, the forming tool 550 (FIGS.11-13) has been retracted therefrom, the composite container 200 isstill in the receptacle 514 a, and the laser beam 580, or the like, fromthe laser 582 is completing the forming of a cut line 594 that separatesthe remnants 556 and the composite web 98 from the composite container.According to one acceptable method for forming the cut line 594, thelaser beam 580 is directed into the opening of the container 150, 200and moved (e.g., by way of the actuator mechanism 584 moving the laser582) all the way around an interior portion of the container proximatethe opening so that the microwave interactive web 208 is cut from thecomposite web 98 and the remnant 556. Typically, none of the remnants556 will be adhered to the preformed container 150, whereas themicrowave interactive web 208 will be adhered to the preformed container150 proximate the cut line 594. More specifically, the microwaveinteractive web 208 will be adhered at substantially the entireinterface between the microwave interactive web and the portion of thepreformed container 150 that is below the cut line 594.

At least in theory, the laser beam 580 may be tuned or otherwisecontrolled (e.g., via the speed at which it is moved), to cut throughthe composite web 98 without cutting into, or only slightly cuttinginto, the preformed container 150. This may require the cutting strengthor dwell time of the laser 582 to be adjusted to compensate forvariations in thickness of the microwave interactive web 208, forexample in the area of the pleats 226 (FIGS. 4 and 6). In this regardand at least in theory, it might be desirable to use a laser cuttersystem (e.g., CNC laser cutter) that can sense variations in thethickness (and/or other attributes) of the microwave interactive web 208(e.g., such as due to pleating) and automatically adjust to them (e.g.,such as by changing the intensity of the laser beam 580, or the speed atwhich it is moved and thus its dwell time) to cleanly cut the microwaveinteractive web 208 from the composite web 98 and remnants 556 withminimal or no damage to the underlying preformed container 150. Anacceptable CNC laser cutter may be available from Preco, Inc. of Lenexa,Kans.

Alternatively, the cutting of the microwave interactive web 208 from thecomposite web 98 and the remnants 556 can be carried out using one ormore “through-cut” reciprocating cutting blades (not shown) (e.g., withjagged teeth). The reciprocating cutter could be a movably mounted jigsaw, or the like, where the movement and other operations of the saw arecontrolled by a computer controller (e.g., a CNC cutting machine thatuses a cutting blade made of metal or other suitable material). In thisexample, around each of the receptacles 514 a-514 e (FIG. 10), theturntable 502 (FIG. 10) may include a blade receiving slot or recess(not shown) in the same pattern in which the through-cut blade is to cutthe microwave interactive web 208 from the composite web 98 and theremnants 556. In one example, the cutting blade is retracted into theslot when not used for cutting. Similarly, the periphery of the dieplate 546 (FIGS. 11-13, 16 and 17) and the anvil 564 (FIGS. 11-13, 15and 17) could be shaped so that the cutting blade travels outwardlyfrom, and around the periphery of, the die plate and the anvil. The jigsaw or other type of mechanical cutter could be replaced with a lasercutter or any other type of suitable cutter.

Other changes can also be made. For example, the microwave interactivewebs 208 may be initially connected to the rest of composite web 98 bytear lines (not shown) (e.g., formed by perforations or spaced apartslits), such that the microwave interactive webs are torn from thecomposite web when respectively forced into the preformed containers150, so that cutting blades, lasers and the like for cutting themicrowave interactive webs from the composite web may be omitted fromthe manufacturing system 500.

Referring to the mounting apparatus 544 (FIGS. 11-13) of the installingapparatus 508 (FIGS. 10-13) in greater detail, FIG. 19 is a schematicperspective view of the mounting apparatus positioned above therepresentative receptacle 514 a, with the forming tool 550 in itsretracted configuration, in accordance with the first exemplaryembodiment. As shown in FIG. 19, the forming tool 550 (e.g., seal head)is mounted to the piston rods of a pneumatic cylinder 600 that ismounted to a frame 602. FIG. 19 is schematic, for example, because forease of illustration the receptacle 514 a is schematically shown as notbeing mounted to the turntable 502 (FIG. 10). Nonetheless andalternatively, the mounting apparatus 544 could be a “stand-alone” unitas generally shown in FIG. 19. That is, although the manufacturingsystem 500 (FIG. 10) of the first embodiment is described hereinprimarily in the context of a machine in which the operations of thevarious components are coordinated so as to continually and seriallyform the composite containers, alternatively the respective componentsof the manufacturing system 500 may not be integrated so that many ofthe steps of forming the composite containers are carried out moreseparately from one another in a batch-type manner. For example, thereceptacle 514 a could be mounted to the frame 602 rather than beingcarried by the turntable 502 (FIG. 10). In additional or alternatively,the receptacle 514 a can be mounted for moving in the same directionthat the forming tool 550 moves (e.g., vertically), such as by thereceptacle 514 a being mounted to, and carried by, a series of springs604, dampers or other flexing mechanisms, as will be discussed ingreater detail below. Typically such springs 604, or the like, formovably carrying the receptacles 514 a-514 e are incorporated into theturntable 502.

As shown in FIG. 19, the mounting apparatus 544 includes a localcontroller 606 that is connected to the overall controller 516 (FIG. 10)of the manufacturing system 500 (FIG. 10) by the signal communicationpath 608 and/or the signal communication path 530 c (FIG. 10). The localcontroller 606 is connected to the pneumatic cylinder 600 by way of oneor more pneumatic lines 610 for controlling actuation of the pneumaticcylinder. Similarly, the local controller 606 is connected to theforming tool 550 by way of one or more electrical lines 612 forcontrolling features of the forming tool and monitoring the formingtool. The local controller 606 is connected to supplies of electricalpower and pneumatic pressure that are not shown in the figures. Thepneumatic cylinder 600 may be replaced with other types of actuators,and similarly the electrical lines 612 and pneumatic lines 610 can bereplaced with any other type of suitable features.

FIG. 20 is a schematic perspective view of a portion of the mountingapparatus 544, and it shows the forming tool 550 in greater detail. Asshown in FIG. 20, the forming tool 550 includes a lower face 614, andside walls 616 along with somewhat rounded corners 618 that extendupwardly/obliquely/outwardly from the periphery of the lower face. Thatis, the shape of the forming tool at least generally corresponds to theshape of the cavity of the preformed containers 150 (FIG. 3) andcomposite containers. As mentioned above, a variety of differentlyshaped preformed containers 150 are within the scope of the presentinvention. Accordingly, a variety of correspondingly differently shapedforming tools 550 are within the scope of the present invention.

FIG. 21 is a schematic perspective view of a portion of the forming tool550 positioned above the representative receptacle 514 a. As shown inFIG. 21, the representative receptacle 514 a includes a base 620, andupstanding walls 622 and somewhat rounded corners 624 that togetherextend around the cavity of the receptacle. The side walls 622 andcorners 624 extend upwardly/obliquely/outwardly from the base 620. Thatis, the shape of the receptacles 514 a-514 e at least generallycorresponds to the shape of the preformed containers 150 (FIG. 3). Asmentioned above, a variety of differently shaped preformed containers150 are within the scope of the present invention. Accordingly, avariety of correspondingly differently shaped receptacles 514 a-514 eare within the scope of the present invention.

FIG. 22 is a schematic perspective view of a portion of the mountingapparatus 544, showing the forming tool 550 in its extendedconfiguration, in which it extends into the receptacle 514 a. As shownin FIGS. 19-22, the shape of the forming tool 550 at least generallycorresponds to the shape of the representative receptacle 514 a,although other relative configurations may be used, as will be discussedin greater detail below. More specifically and in accordance with oneexample, the shape and size of the forming tool 550, the shape and sizeof the cavity defined by the receptacle 514 a, the shape and size of thecavity defined by the microwave interactive web 208 of the compositecontainer 200, and the shape and size of the cavity defined by thepreformed container 150 substantially correspond to one another,although the sizes vary sufficiently to facilitate the tightly nestedconfigurations that are at least partially shown in FIGS. 13 and 22.

Ideally, the microwave interactive web 208 is joined to the preformedcontainer 150 in the receptacle 514 a with substantially no unbondedportions and substantially no air gaps between the microwave interactiveweb and the preformed container. However, each composite container 150may exhibit dimensional variations and, therefore, may not be sealed inthe same manner or to the same extent. In an effort to mitigate thisvariability, the receptacles 514 a-514 e and/or the forming tool 550 maybe designed in various ways to improve the seal between the preformedcontainers and the microwave interactive webs. For example, all or aportion of the forming tool 550 may be formed from a somewhat compliantmaterial, for example, a silicone elastomer or other material, toimprove contact between the microwave interactive web 208 and thepreformed container 150. Additionally, by using a compliant material toform the forming tool 550, it is possible to use a forming tool thatinitially has greater dimensions than those of the interior of thepreformed container 150, thereby further improving contact between themicrowave interactive web 208 and the preformed container 150. Theremaining portions of the forming tool 550 may be made from a relativelylight-weight, conductive material, such as aluminum or any othersuitable material.

If desired, the lower face 614 of the forming tool 550 and/or the base620 of the receptacles 514 a-514 e may include a protrusion (e.g., anarcuate protrusion) or otherwise be crowned, or the like, to create aninitial point of contact between the microwave interactive web 208 andthe preformed container 150, as shown schematically in FIG. 23. Morespecifically, FIG. 23 is a schematic, cross-sectional view showing howthe forming tool 550 and the representative receptacle 514 a can beshaped, with the cross-section being taken vertically through the centerof the forming tool and the representative receptacle, and only thecross-section being shown. As the forming tool 550 advances toward thepreformed container 150, the contact area between the microwaveinteractive web 208 and the preformed container increases from thecenter, thereby gradually forcing the air outwardly from between themicrowave interactive web and the preformed container. As a result, asmooth, tight seal between the microwave interactive web 208 and theinterior surface of the preformed container 150 may be formed.

Alternatively, the forming tool 550 may be designed to: expand in use toincrease contact between the microwave interactive web 208 and preformedcontainer 150, and then contract upon formation of the seal between themicrowave interactive web and preformed container.

As another example, the receptacles 514 a-514 e may be designed to allowthe dimensions of the receptacles 514 a-514 e to adjust as needed toconform to the outer dimensions of the preformed containers 150. Forexample, the interior of each of the receptacles 514 a-514 e may beformed from a flexible material, such as a natural or synthetic polymer,for example rubber, that conforms to and grips the exterior of thepreformed container 150 as the forming tool 550 presses the microwaveinteractive web 208 against the preformed container 150.

As another example, with the representative receptacle 514 a beingmovably mounted, such as by being mounted to the springs as shown inFIG. 19, the receptacle 514 a can move to accommodate for a wide varietyof variations that might occur, such as due to varying tolerances thatmay exist in a wide variety of the features of the present invention.

In another example, the base 620 of the representative receptacle 514 amay be vertically movable relative to the side walls 622 of therepresentative receptacle, such as by the side walls 622 being fixedlymounted to the turntable 502 (FIG. 10) or the frame 602 (FIGS. 19, 21and 22) and the base 620 being movably carried by the springs 604,dampers or other flexing mechanisms. This arrangement could allow thepreformed container 150 to be inserted more deeply and snugly into therepresentative receptacle 514 a. Further regarding this“self-tightening” feature, as the forming tool 550 brings the microwaveinteractive web 208 into contact with the preformed container 150, thepreformed container is pressed further into the representativereceptacle 514 a against the spring-loaded bottom, and the forcestypically increase as the springs are compressed, due to the increasedresistance provided by the springs as they are compressed further.

In some circumstances, the composite containers may become lodged withinthe receptacles 514 a-514 e as a result of the force asserted by theforming tool 550. As such, the manufacturing system 500 may includevarious features to prevent the composite containers from being pressedtoo far into the receptacles 514 a-514 e. Alternatively, themanufacturing system 500 may include various features to dislodge thepreformed containers if they become lodged in the receptacles 514 a-514e. For example, a blocking or arresting feature (not shown) may beincluded within the receptacles 514 a-514 e to prevent the compositecontainers from being forced too far into the receptacles.Alternatively, one or more ejection features may be associated with thereceptacles 514 a-514 e. For example, a mechanical ejection pin (notshown) or the like may be forced into the cavity of a receptacle to helpeject a composite container from the receptacle. Similarly, one or moreports other types of openings or passages may be associated with thereceptacles 514 a-514 e, so that compressed air or another medium can beblasted into or otherwise introduced into the cavity of a receptacle tohelp eject a composite container from the receptacle.

As another example and as discussed in greater detail below withreference to the third exemplary embodiment of the present invention(e.g., see the below discussion about FIG. 29), the forming tool 550 mayinclude one or more vacuum ports for having a partial vacuum supplied tothe face 614 of the forming tool to cause the microwave interactive webto be held securely by the forming tool throughout the plunge stroke.Such ports also may be used to aid in releasing the microwaveinteractive web from the forming tool 550 after the microwaveinteractive web becomes part of a composite container, such as by beingused to blast compressed air or another medium against the microwaveinteractive web. The forming tool 550 also may include a mechanicalejection pin or other device to help the forming tool release acomposite container that inadvertently becomes stuck to the formingtool.

Referring back to FIG. 10, after the composite container 200 is formedin the receptacle 514 a and separated from the remnants 556 and thecomposite web 98 at the third position that is shown in FIGS. 11-13, theturntable 502 is rotated to the next position, so that the receptacle514 a containing the composite container 200 is adjacent to thepost-treating apparatus 510. At this “fourth” position, the optionalpost-treating apparatus 510 can post-treat the composite container 200in the receptacle 514 a.

Depending upon which of the options for manufacturing the compositecontainers is used, and the tolerances that are chosen or otherwiseexits, a peripheral edge of the microwave interactive web 208 of thecomposite container 200 may be a flap-like feature that is not adheredto the preformed container 150. Such an unadhered edge/flap-like feature630 is schematically shown in FIG. 24. FIG. 24 is a schematic, verticalcross-sectional view of a portion of the composite container 200,showing how a peripheral edge of the microwave interactive web 208 ofthe composite container may be a flap-like feature 630 that is notadhered to the preformed container 150, in accordance with a version ofthe first exemplary embodiment of the present invention. As partiallyshown in FIG. 24, the flap-like feature 630 can extend around the entireperiphery of the microwave interactive web 208. Alternatively, theflap-like feature 630 may not be formed, or it may only be formed at oneor more segments of the periphery of the microwave interactive web 208that are spaced apart from one another.

The post-treating carried out by the post-treating apparatus 510 (FIG.10) can be a heat treatment. In this regard, FIG. 25 is like FIG. 24,except that it shows that the flap-like feature 630 has been transformedinto a bead 632, such as through a post-treatment heating process, inaccordance with a version of the first exemplary embodiment of thepresent invention. As partially shown in FIG. 25, the bead 632 canextend around the entire periphery of the microwave interactive web 208.Alternatively, the bead 632 may not be formed, or it may only be formedat one or more segments of the periphery of the microwave interactiveweb 208 that are spaced apart from one another. The bead 632 istypically in the form of a small globular or cylindrical or bulbousbody. As apparent from comparing FIGS. 24 and 25, the bead 632 istypically shorter and fatter/thicker than the flap-like feature 630 fromwhich it was formed. That is, the bead 632 is typically thicker than themicrowave interactive web 208, or at least thicker than the polymer filmsubstrate 112 of the microwave interactive web 208.

In some situations, it may be desirable to ensure that the portion ofthe microwave interactive web 208 that includes any microwaveinteractive material is securely adhered to the previously formedcontainer 150 such that the flap-like feature 630 consist solely of thepolymer film substrate 112. In these situations, the bead 632 will beformed solely from the polymer film substrate 112. Nonetheless,different configurations are also within the scope of the presentinvention, as discussed in greater detail below.

FIGS. 24 and 25 are schematic because, for example, they exaggerate theflap-like feature 630 and bead 632. For example, in practice, the bead632 would be small and barely noticeable with the naked eye. The bead632 will typically accumulate at the boundary where the film substrate112 has been well adhered to the interior surface of the preformed tray150 or the flange 158 of the preformed tray. In accordance with oneexample of the first embodiment, the film substrate 112 may be very thin(e.g., about 0.00048 inches thick) and the width W (FIG. 24) of theflap-like feature 630 may be less than ⅜ of an inch; therefore, a verysmall volume per lineal inch of film edge (approximately 0.00018 cubicinches per lineal inch) would constitute the bead 632 left aftershrinkage of the flap-like feature 630.

As alluded to above, the shrinkage of the flap-like feature 630, whichcreates the bead 632, or the like, can be caused by the application ofheat. In one example, the flap-like feature 630 is exposed to sufficientheat to raise its temperature above its heat set temperature, whichcauses rapid and significant shrinkage of the flap-like feature 630, sothat it is transitioned into the bead 632, or the like. A short durationof heat application may be sufficient to cause this shrinkage, forexample because the thermal mass of the flap-like feature 630 of thefilm substrate 112 is small compared to that of the flange 158 and bodyof the composite container 200.

The post-treating apparatus 510 (FIG. 10) can include a downwardly openchamber that defines a cavity that is open to and in receipt of thecomposite container 200 in the receptacle 514 a while the receptacle 514a is in the fourth position. The chamber of the post-treating apparatus510 can be in the form of an oven that includes one or more heatingelements, blowers or any other suitable mechanism for heating thecomposite container 200 in the receptacle 514 a. For example, thepost-treating apparatus 510 can operate such that the entire cavity ofthe post-treating apparatus is heated to about the same temperature, orthe increased temperature may be directed more specifically to the areawhere it is desired (i.e., the flap-like feature 630), such as throughthe use of one or more electromechanical devices designed to (andmounted for) blowing hot air at the targeted areas. More specifically,each of the electromechanical devices can include coils of wire, whichhave a high electric resistivity and that heat rapidly as current flowsthrough them, a fan that blows ambient through the hot coils, and apassageway through which the heated air is directed to the targetedarea. More generally these electromechanical devices can be referred toas hot air guns. The heating with the post-treating apparatus 510 canalso or alternatively be provided by way of gas flames.

As mentioned above, it may be desirable in some situations for theentire portion of the microwave interactive web 208 that includes themicrowave interactive material (e.g., the first and second microwaveinteractive elements 212, 214 of FIGS. 4 and 14) to be securely adheredto the previously formed container 150 such that the flap-like feature630 consist solely of the polymer film substrate 112. On the other hand,in some situations the flap-like feature 630 can include a thin layer ofmicrowave interactive material that tends to absorb microwave energy,thereby generating heat when exposed to microwave energy. For example,the microwave interactive web 208 may be or include a MICRORITE®susceptor available from Graphic Packaging International, Inc.(Marietta, Ga.), and the flap-like feature 630 may include a portion ofthis or another type of susceptor. When the flap-like feature 630includes a thin layer of microwave interactive material that tends toabsorb microwave energy, the post-treating apparatus 510 may be at leastgenerally in the form of a microwave oven, or the like, so that thesusceptor-like flap-like feature 630 shrinks to form/transforms into thebead 632 in response to being exposed to a short application ofmicrowave energy. The heating of the flap-like feature 630 thattransforms it into the bead 632 typically occurs prior to loading thecomposite container 200 with contents such as food (not shown).

Referring back to FIG. 10, after the composite container 200 ispost-treated at the fourth position, the turntable 502 is rotated to thenext position, so that the receptacle 514 a containing the compositecontainer 200 is adjacent to the receiving apparatus 512. At this“fifth” position, the composite container 200 is removed from thereceptacle 514 a and stacked in a nested configuration for later use orotherwise prepared for further processing. The receiving apparatus 512can be any suitable device for removing the composite container 200 fromthe turntable 502. For example, a pick-and-place machine, such asdescribed above, may be used. After the turntable 502 comes to rest withthe receptacle 514 a in the fifth position, the composite container 200within the receptacle 514 a is grasped and removed from the receptaclesuch as by the pick-and-place machine. It then may be placed in a nestedstack 634 that is processed using any conventional devices or equipment.For instance, the nested stack 634 may be manipulated by an indexingconveyor system in which a counting device detects that the stack 634has reached the correct height and quantity and signals the conveyor tomove the finished stack 634 to another location for subsequentprocessing or shipping. A new stack is started, and the cycle repeatsitself.

In another example, the receiving apparatus 512 can be an “up-stacking”mechanism located proximate the final position, in this example, thefifth position. In this example, the finished composite container 200 ispushed upward and out of the receptacle 514 a and directly into thestack 634 that is being formed directly above the receptacle 514 a. Asdiscussed immediately above, when the stack 634 of composite containers200 reaches the correct height and count, it is repositioned and a newstack is started.

The operations described above with respect primarily to the receptacle514 a are repeated numerous times in a serial fashion for each of thereceptacles 514 a-514 e so that the manufacturing system 500 createsnumerous composite containers 200 in a serial fashion. As one example,the computer processor, or the like, of the central controller 516 canrun/execute a software program/one or more software modules that areaffective so that the central controller 516 is responsive to and/orrespectively provides signals over the signal communication paths of themanufacturing system 500 with respect to local controllers of themanufacturing system to control and coordinate the operations of themanufacturing system. Those of ordinary skill in the art will be able toprovide suitable hardware and software for these purposes. Whereas theoverall control of the manufacturing system 500 is described above asbeing dominated by electronic hardware and software, or the like, atleast some of the overall control system of the manufacturing system 500can alternatively include one or more of mechanical or pneumatic controlsystems, or any other type of suitable control systems.

One of the numerous advantages of the manufacturing system 500 andassociated methods of the present invention is that they can provideflexibility in the manufacture of composite containers. As one exampleof this flexibility, a multi-compartment container with more than onecavity (e.g., a container with one or more interior walls or dividersthat separate the cavities/food items or multiple servings of aparticular food item) can have different types of microwave interactivewebs respectively mounted in its cavities, with the mounting of each ofthe webs in its respective cavity being carried out generally asdescribed above. For example and referring to FIG. 10, there could betwo or more of the installing apparatuses 508 that are side by side atthe third position. Alternatively, multi-compartment containers could besupplied to the manufacturing system 500 two or more times, with themanufacturing system reconfigured accordingly for the first andsubsequent passes through the manufacturing system, so that thedifferent cavities of a container respectively have microwaveinteractive webs mounted therein during the container's passes throughthe manufacturing system.

As one specific example, FIG. 26 is a schematic top plan view of amulti-compartment composite container 640 in accordance with a versionof a second exemplary embodiment of the present invention. The secondembodiment is like the first embodiment, except for variations noted andvariations that will be apparent to those of ordinary skill in the art.For example, the multi-compartment composite container 640 is like theabove-discussed composite containers, except that it includes an uprightbarrier 642 (e.g., a middle wall), or the like, so that themulti-compartment composite container includes two cavities that areside by side. As schematically shown in FIG. 26, a first cavity 644 ofthe two cavities has mounted therein a microwave interactive web 208 ofthe type discussed above with reference to FIGS. 4 and 14, whereas thesecond cavity 646 of the two cavities has mounted therein a microwaveinteractive web 308 of the type discussed above with reference to FIG.8. Accordingly, the microwave interactive web 208 in the first cavity644 may be distinct from the microwave interactive web 308 in the secondcavity 646. Alternatively, the microwave interactive web 208 in thefirst cavity 644 may be similar to or the same as the microwaveinteractive web 308 in the second cavity 646. In accordance with analternative embodiment that is not illustrated in the drawings, themicrowave interactive webs 208, 308 that are distinct from one anotherare positioned in the same cavity.

In the embodiment of FIG. 26, each of the microwave interactive webs208, 308 may be mounted in its respective cavity 644, 646 at leastgenerally as discussed above for the first embodiment of the presentinvention, such that the microwave interactive webs of themulti-compartment composite container 640 are typically not directlyconnected to one another. In addition, any of the microwave interactivewebs disclosed herein can be substituted for the microwave interactivewebs shown mounted in the first and second cavities 644, 646, and eitherof the first and second cavities may not have any microwave interactiveweb mounted therein, such that a wide variety of combinations arepossible. Although the first and second cavities 644, 646 are about thesame size in FIG. 26, they can be differently sized and there can bemore than two cavities in the same multi-compartment compositecontainer. That is, a variety of differently shaped multi-compartmentcontainers, with different numbers of cavities and different microwaveinteractive webs, are within the scope of the present invention.

In accordance with a second version of the second embodiment, themicrowave interactive webs 648, 650 schematically shown in FIGS. 27 and28 are respectively substituted for the microwave interactive webs 208,308 mounted in the first and second cavities 644, 646 of themulti-compartment composite container 640 of FIG. 26 to create adifferent multi-compartment composite container. In accordance with thesecond version of the second embodiment, the preformed multi-compartmentcomposite container is formed from polyethylene terephthalate, forexample coextruded polyethylene terephthalate, and the microwaveinteractive webs are a patterned foil film (7 micron thick aluminum on48 gauge PET). In the second multi-compartment composite container, thecavity having the microwave interactive web 648 of FIG. 27 mountedtherein can be characterized as a first compartment, and in one examplemeatloaf (not shown) or another meat product is contained in the firstcompartment. The cavity having the microwave interactive web 650 of FIG.28 mounted therein can be characterized as a second compartment, and inone example potatoes or other vegetables are contained in the secondcompartment.

In the foregoing, the preformed containers (e.g., preformed container150 of FIG. 3) were originally and more generally referred to aspreformed supports. The preformed supports may, in isolation, not be inthe form of containers (e.g., they may include holes, or other openingssuch that the containers are not formed until the preformed supports andthe microwave interactive webs are mounted together. In one example, themicrowave interactive webs comprise a “shrink film”, and an exemplarymethod includes overlying a preformed support with the microwaveinteractive web, and activating the web (i.e., the shrink film) tocreate a uniform, tight seal between the microwave interactive web andthe support, and thereby create a container (e.g., a composite containeror a multi-compartment composite container that is at least generally asdescribed above).

A third exemplary embodiment of the present invention is like the firstembodiment and/or second embodiment, except for variations noted andvariations that will be apparent to those of ordinary skill in the art.FIG. 29 is a schematic, partially cross-sectioned view of a forming tool660 associated with a vacuum pump 664, or the like, in accordance withthe third exemplary embodiment of the present invention. As generallyshown in FIG. 29, the face of the forming tool 660 of the thirdembodiment is shaped at least generally like the face of the formingtool 550 of the first embodiment, except that the forming tool 660further includes vacuum ports 662 to which a partial vacuum is suppliedby way of a chamber within the forming tool 660 and the vacuum pump 664,or the like. As shown in FIG. 29, the vacuum pump 664 draws air from theinternal chamber of the forming tool 660 that is in communication withthe vacuum ports 662.

In accordance with the third embodiment, any of the above-discussedmicrowave interactive webs, such as the microwave interactive web 208 ofFIG. 14, can be placed over or otherwise associated with the face of theforming tool 600 while the partial vacuum is provided to the face of theforming tool. For example, FIG. 30 shows the microwave interactive web208 drawn to the face of the forming tool by the partial vacuum suppliedto the face of the forming tool, so that the microwave interactive webis conformed to the shape of the face of the forming tool to create athree-dimensional microwave interactive structure 666. FIG. 31 is aschematic, isolated perspective view of the three-dimensional microwaveinteractive structure 666 of FIG. 30. As apparent from FIGS. 30 and 31,the forming tool 660 extends into and shapes the cavity of thethree-dimensional microwave interactive structure 666. Thethree-dimensional microwave interactive structure 666 includes a base668 as well as walls 670 and corners 672 that together extend around thecavity of the three-dimensional microwave interactive structure. Thewalls 670 and corners 672 extend obliquely/outwardly from the base 668.

In one acceptable example of a first version of the third embodiment,the composite container 200 of FIG. 4, or a composite construct that isat least generally like the composite container 200 of FIG. 4, is formedby mounting (e.g., adhering) the preformed container 150 of FIG. 3 tothe three-dimensional microwave interactive structure 666 while thethree-dimensional microwave interactive structure is held to the face ofthe forming tool 660. As one option, the microwave interactive web208/three-dimensional microwave interactive structure 666 may have aheat seal coating or other adhesive applied to the surface thereof thatis facing away from the forming tool 660. More generally, the adheringcan be facilitated by an adhesive material, heat seal coating, thermalbonding, ultrasonic bonding, or any other suitable technique. Theforming tool 660 may be heated if needed or desired, for example, toactivate a heat seal coating used to mount the preformed container 150to the three-dimensional microwave interactive structure 666.

In one example of a second version of the third embodiment, a compositecontainer 200′ (FIG. 34) that is like the composite container 200 ofFIG. 4, except for variations noted and variations that will be apparentto those of ordinary skill in the art. The composite container 200′ isformed through the use of a modified microwave interactive web 208′ andthree-dimensional microwave interactive structure 666′ that arerespectively like the above-discussed microwave interactive web 208 andthree-dimensional microwave interactive structure 666 of the firstversion of the third embodiment except for having slits or otherphysical apertures 674 extending completely therethrough, as shown inFIG. 32. The apertures 674 are sufficient in number and/or arrangementso that the partial vacuum at the face of the forming tool 660 bothdraws the microwave interactive web 208′ and the three-dimensionalmicrowave interactive structure 666′ to the face of the forming tool 660and causes a partial vacuum to be present at the face of thethree-dimensional microwave interactive structure 666′ that faces awayfrom the face of the forming tool 660. The microwave interactive web208′/three-dimensional microwave interactive structure 666′ may have aheat seal coating or other adhesive material on its side that faces awayfrom the forming tool 660.

As schematically shown in FIG. 33, a polymer sheet 676, for example, asheet of polyester or coextruded polyethylene terephthalate, is placedover the microwave interactive web 208′/three-dimensional microwaveinteractive structure 666′. Typically the polymer sheet 676 will beheated to a sufficient degree (or otherwise processed) so that it issufficiently flexible so that the partial vacuum draws the polymer sheettoward the three-dimensional microwave interactive structure 666′ andforms the polymer sheet 676 into the desired shape. In doing so, thepolymer sheet 676 and the three-dimensional microwave interactivestructure 666′ are joined with the heal seal coating or adhesive, or byany other acceptable means, to form the composite container 200′schematically shown in FIG. 34. Typically after the polymer sheet 676has been adhered to the three-dimensional microwave interactivestructure 666′ and conformed to the shape of the forming tool 660, thepolymer sheet is allowed to cool enough (or is otherwise processed) sothat it becomes sufficiently rigid to remain in the shape it has adoptedfrom the forming tool. Then, the composite container 200′ is removedfrom the forming tool 660, so that the next three-dimensional microwaveinteractive structure 666′ and composite container 200′ can be formedthereon.

It is also within the scope of the present invention for the compositecontainers (including the multi-compartment composite containers) tohave the microwave interactive webs respectively mounted to the exteriorsurfaces (instead of the interior surfaces) of the correspondingsupports (e.g., preformed containers).

It will be understood by those skilled in the art that while the presentinvention has been discussed above with reference to exemplaryembodiments and examples of versions of the embodiments, variousadditions, modifications and changes can be made thereto withoutdeparting from the spirit and scope of the invention as set forth in thefollowing claims.

What is claimed is:
 1. A system for at least forming constructs thatinclude microwave interactive material, the system comprising: acontainer transporting apparatus for serially moving containers along afirst path of travel; a web transporting apparatus for serially movingmicrowave interactive webs along a second path of travel, wherein atleast a portion of the first path of travel and a portion of the secondpath of travel are superposed with respect to one another so that thecontainers and microwave interactive webs are superposed with respect toone another in a serial fashion; and a mounting apparatus for mountingat least one of the microwave interactive webs to at least one of thecontainers while the at least one of the microwave interactive webs andthe at least one of the containers are in a superposed arrangement withrespect to one another, wherein the mounting apparatus includes aforming tool for at least partially forming at least one cavity of theat the at least one of the microwave interactive webs so that the cavityis present during the mounting of the at least one of the microwaveinteractive webs to the at least one of the containers.
 2. The systemaccording to claim 1, wherein the container transporting apparatuscomprises a conveyor including a plurality of receptacles configured forserially traveling along an endless path, the system further includes asupplying apparatus for depositing the containers in the receptacles, sothat the receptacles carry the containers; the mounting apparatus ispositioned along the endless path so that the receptacles carry thecontainers, with the microwave interactive webs respectively mountedthereto, in a downstream direction along the endless path and away fromthe mounting apparatus; and the system further includes a receivingapparatus that is positioned along the endless path at a positiondownstream from the mounting apparatus, with the receiving apparatusbeing for receiving the containers, with the microwave interactive websrespectively mounted thereto, from the container transporting apparatus.3. The system according to claim 2, further comprising a treatingapparatus positioned along the endless path at a position between themounting apparatus and the receiving apparatus, wherein the treatingapparatus is for treating at least marginal edges of the microwaveinteractive webs of the containers.
 4. The system according to claim 1,wherein the forming tool comprises a pusher for pushing the at least oneof the microwave interactive webs at least partially into a cavity ofthe at least one of the containers.
 5. The system according to claim 4,wherein the pusher is mounted for reciprocating along an axis.
 6. Asystem for forming containers including microwave interactive material,the system comprising: an installing apparatus including a forming tool;a web transporting apparatus for serially providing microwaveinteractive webs to the installing apparatus; and a support transportingapparatus for serially supplying supports to the installing apparatus,wherein the installing apparatus is operative to serially combine themicrowave interactive webs and the supports to form the containers, sothat each container includes at least one of the supports supporting atleast one of the microwave interactive webs, with the at least one ofthe microwave interactive webs extending at least partially around andat least partially defining a cavity of the container, and the formingtool extends at least partially into the cavity of the container to atleast partially facilitate mounting of the at least one of the microwaveinteractive webs to the at least one of the supports.
 7. The systemaccording to claim 6, further comprising a treating apparatus forserially treating the containers, with the treating of the containerscomprising treating at least marginal edges of the microwave interactivewebs of the containers.
 8. The system according to claim 6, wherein theinstalling apparatus, the web transporting apparatus and the supporttransporting apparatus are cooperative so that the at least one of themicrowave interactive webs is positioned between the forming tool andthe at least one of the supports.
 9. The system according to claim 6,wherein: the web transporting apparatus, which is for supplying themicrowave interactive webs to the to the installing apparatus, comprisesa reel for carrying a roll from which a composite web, which includesthe microwave interactive webs, is drawn; and the system comprises acutter for cutting the microwave interactive webs from the compositeweb.
 10. The system according to claim 9, wherein: the composite web andthe cutter are cooperative so that remnants of the composite web resultfrom the cutting the composite web; and the system further comprises aremnant collector for collecting at least some of the remnants of thecomposite web.
 11. The system according to claim 10 wherein the remnantcollector comprises a reel for rolling the remnants onto a roll.
 12. Thesystem according to claim 6, wherein: the support transporting apparatusincludes at least one receptacle having at least one cavity; the formingtool and the receptacle are mounted with respect to one another so thatthere can be relative movement between the forming tool and thereceptacle so that the forming tool and the receptacle can betransitioned between an inserted configuration in which the forming toolis at least partially inserted into the cavity of the receptacle, and aretracted configuration in which the forming tool is at least partiallyretracted from the cavity; and the installing apparatus includes atleast one actuator for causing relative movement between the formingtool and the receptacle, to transition between the retracted andinserted configurations.
 13. The system according to claim 12, whereinat least one of the forming tool and the receptacle is heated.
 14. Thesystem according to claim 12, wherein: the installing apparatus furtherincludes an apparatus for creating a partial vacuum at a face of theforming tool; and the face of the forming tool is for being in opposingface-to-face relation with the microwave interactive webs.
 15. A systemfor forming at least one container including microwave interactivematerial, the system comprising: a holder for releasably holding atleast one microwave interactive web; an apparatus for supporting atleast one support; and a forming tool mounted for moving relative to theapparatus to thereby move the microwave interactive web relative to thesupport and at least partially form the container, so that the formingtool extends at least partially into a cavity of the container, whereinthe holder is configured for at least tensioning the microwaveinteractive web while the forming tool moves the microwave interactiveweb relative to the support.
 16. The system according to claim 15,wherein the holder defines at least one gap for slidingly receiving themicrowave interactive web.
 17. The system according to claim 16, whereina distance extending across and perpendicular to the gap is about thesame as a thickness of the microwave interactive web.
 18. The systemaccording to claim 16, wherein the gap defines an undulating shape. 19.The system according to claim 16, wherein the holder comprises a pair ofdies, and the gap is at least partially defined between the pair ofdies.
 20. The system according to claim 19, wherein a first of the diesis a female pleating die, and a second of the dies is a male pleatingdie.